In this dissertation, reverse hot extrusion process of copper metal is investigated and then a test sample is designed and manufactured. First, using geometry of the required samples, the billet size was estimated, and then using simulation software, the billet and die are designed and analyzed. To design the die, the reverse extrusion design guidelines mentioned in die design handbooks are used, and heat losses can be predicted by estimating heat transfer coefficients between ambient air and the work piece, work piece and the die. Also estimation of friction coefficient for this process and friction modeling method was another challenge of this project. In the modeling of the process, selection of element type and solution method was studied, and finally Lagrangian solution was used. In the simulation, effect of design parameters such as increasing extrusion ratio, die angle, eccentricity of punch and die, initial temperature and radius of the punch edge are discussed. From the simulation results estimated punch forces required to perform the operation are obtained for all affecting parameters. All simulations are performed by the DEFROM software and considering all required steps such as geometry, definition of boundary conditions, selection solution type and discretization of the model and other items. Simulation results show that with increasing the extrusion ratio, the required force and stress levels in the die which is one of the most important parameters, increase. As the part temperature, radius of the punch edge and the angle of the die opening increases, the force required for the extrusion operation decreases. For validation, the results of a similar study with the current study were compared, in which a similar sample by reverse extrusion was analyzed in DEFORM software. One of the important factors in performing this process is to predict the die life, which has a great impact on determining the cost of the product. Therefore, an attempt has been made to provide an approximate method for predicting product life. To estimate the die life, a similar hot backward extrusion process was used, in which the die life was experimentally known. y simulating of that process, the stresses in the die was calculated. Then by comparing the stress levels in two processes, die life could be estimated. After a general evaluation of the parameters, the required die was simulated and all stresses on all die components including die, punch and other components were calculated. Then, after these calculations, the die was made for practical testing. The work piece and die needed preheating for practical testing, for which the billet was preheated by an induction furnace and the die was preheated by a flame torch. One of the most important factors in extrusion is the type of lubricant. In this project, using experience and research, molybdenum lubricant, graphite and oil have been used to improve the product surface and operations with less force. After the forming operation, hardness and product surface quality tests were performed on the samples. Keywords: Die design, Hot Extrusion, Copper Extrusion