Abstract: The paper aims to study the forming process and die structure of large size GH4169 superalloy bolt in order to solve the problems of difficult forming, easy cracking and low service life of the die. Combined with the theory of metal plastic forming, the forming process scheme is put forward. The proposed process scheme is numerically simulated by Deform-3D finite element analysis software. The load stroke curve and metal flow law in the forming process are analyzed. According to the forming process, the corresponding die structure is designed and optimized. Finally, the process test is carried out. Through numerical simulation, the process parameters in the forming process are obtained, and the deformation mechanism of GH4169 superalloy bolt forming process is revealed. When the double-layer prestressed composite die is used, the die cracks. After the die structure is optimized, the three-layer prestressed composite die is used to meet the forming requirements, the die life is high, and the GH4169 superalloy bolt forgings trial produced in small batch are fully filled. The data obtained are basically consistent with the simulation results. The forming process and die structure of GH4169 superalloy bolt proposed in this paper are feasible. The formed superalloy bolt meets the practical application requirements in the aerospace field, provides a certain theoretical basis for the production of large-size GH4169 superalloy bolt, and has guiding significance for the actual production and other similar parts.