This study reports on the optimisation of the forging process using Deform™ 3D simulation software and the Taguchi method. The forging simulation process was conducted on X20 steel used because of its application in boiler pipes in the fossil-fuel power plants. A three-level, three parameter Taguchi design of experiment for the Deform 3D simulations was used. The parameters considered for the simulations were cylinder (deformation) temperature, die speed and friction coefficient were studied. From the forging process, simulation results were analysed using Taguchi’s orthogonal array. Further, ANOVA analysis was carried out to determine the significance of the parameters to the forging responses (maximum tensile stress and forging force). Results of the statistical analysis showed that the optimal parameters for improved product quality were deformation temperature of 1000 °C, die speed of v 20 mm/s and friction coefficient of 0.2. A confirmatory simulation was carried out using the optimal parameters. The simulation results verified that the optimal parameters showed a lower maximum tensile stress to 252.5 ± 2.5 MPa at the lateral surface of the deformed sample compared to other investigated conditions.