Considering the developments in industry, old fashioned manufacturing processes are being replaced by more sophisticated methods. That being said, each new manufacturing method can be considered as the same old manufacturing process which is well optimized. One of the most prominent processes in manufacturing of brass parts, is forging which is still highly applicable due to its unique advantages. One of the disadvantages of forging in old fashion method is that a great portion of the material is wasted through flash. In order to reduce the amount of wasted materials, new forging techniques have been developed, mostly known as flashless forging. Specially, for costly materials such as brass, such reduction in wasted materials can pronounce significant importance. In the present study, the forging process of ½” gas valve has been simulated which is quite impressive, from simulation point of view. In the first step, the current industrial process was identified and simulated so which the flaws and problems could be specified thoroughly. Following this, suggestions were made to improve the process. It was observed that not only the problems of the process were eliminated, but also the forging force was reduced by 22%. In the next step, three different die designs for flashless forging technique have been proposed. Among these three dies, the die with controlled flash was rejected, because the die was not fully filled in the very initial steps of simulation. From two other die designs, only the conventional flashless die was approved. The flashless die with special punch was rejected due to dramatic increase of stress, observed in one of the punches which eventually brought the assumption of very low fatigue life of the punch. Conventional flashless forging die has 30% greater forging forces, in comparison with improved conventional forging die with flash. Consequently conventional flashless dies expose greater stresses to its components and has shorter fatigue life. However, conventional flashless forging die has 12% greater tool wear, compared with improved conventional forging die with flash. The cost of flashless dies is less and the production rate would be increased due to elimination of trimming process. It was observed that the temperature of the die and work-piece was increased slightly. In general, the initial billet weight, which was 164gr, was reduced by 24gr which is a significant improvement in mass production. Therefore, by spending more effort in tool selection and accessories such as billet trimmer saw the design can be proposed to the industry. Billet trimmer saw tolerances more than 0.2 mm causes either damage to the die or not fill it. By utilizing this design in industry, production rate would be increas ed while the production costs can be reduced dramatically. Key words: Finite element method, Hot Forging, Flashless Forging, Forging Force, Die Temperature, Effective Stress, Die Life.