In order to solve the problems of complex machining process and low production efficiency for a kind of automotive piston shaft sleeve, a production mode combining forging and cutting was put forward. In order to reduce the process risk, Deform-3D software was used to simulate the forging process. The results show that there are forming defects in the composite upsetting extrusion station and the final upsetting station. And the causes of the defects are determined according to the metal deformation process.The forging process scheme was adjusted, including the change of billet sizes and the optimization of die structures at each station. A new forming simulation was conducted on the adjusted forging process. The result shows that the metal deformation is reasonable, the filling of parts is complete, and there is no defects, achieving the expected forming results. Based on the guidance of simulation test, the production practice of piston shaft sleeve was completed. The forging results are good, and there are no defects in each station, which are consistent with the prediction results. The adoption of this process not only accelerates the production speed of piston shaft sleeves, but also increases the material utilization rate from 25.7% to 77.0%, significantly reducing costs.