Abstract: Forging is one of the most important methods for manufacturing the complicated parts. In this study die designing of the conical gears are considered by using of the modern methods. Conical gears are one of the extensively used components in automotive industry. Preferred fibrous structure which can bear highly dynamics loadings and cost effectiveness are the most considerable characteristics of forging process in producing gears. Various flaws like un-filling, overlap and crack can cause defect in the final part quality which most of them are due to inappropriate design of preform dies. In this paper using both numerical and physical methods, three forging steps for producing a conical gear are performed and compared. The results obtained from simulation and the Physical methods show that the accuracy of method is high and acceptable. With these results die designer can have better idea about optimized design.