In aluminum extrusion the life of the die tooling components are mainly limited by wear and fatigue. Therefore reliable predictions of the amount of wear and its distribution in dies are important factors for the die manufacture [2]. Using Deform 3D a comparative study of varying thickness of Titanium CarboNitired (TiCN) was simulated on the modular die design mandrel and die plate to understand the effects of coating thickness on extrusion load, extrudate exit velocity, pressure distribution and tool wear that can be occur during hot aluminum extrusion. The results generated from the simulation would help predict the service life of the components, would also help in optimizing the right amount of thickness needed for the coating to improve die life.