To solve the material folding problem of automotive threaded pipe fittings during the die trial experiment of seven-station cold heading, the plastic flow characteristics of the actual cold heading material were obtained by the cold compression experiment, and the forming simulation of the current process was completed by the volume forming software Deform-3D. Then, by comparing the numerical simulation and the actual cold heading results, the reliability of the simulation experiment was verified. At the same time, the process and reasons for local station defects were introduced in detail, and the reasonable improvements were made. Furthermore, the forming process of the parts in the improved station was simulated, and the forming situation after improvement was tested. The results show that the material flow situation is greatly improved, not only the original folding defects are eliminated, but also the forming of the part shape meets the expectation. Finally, the die trial experiment of cold heading is carried out according to the improved process, and the cold heading results are exactly the same as the simulation results. There are no folding defects in the part of each station and the final threaded pipe fittings, and the forming quality is good, indicating that the new process is feasible, and the production of threaded pipe fittings can be significantly increased.