In this paper, experiences gained at Norm Fasteners Co. on FE simulation utilization are explained with case studies examples. The early simulation models in the company belonged to axisymmetric, one stroke forging processes. As the results of those simple models have been verified by experiments and measurements, the simulation ability in the company expanded, so currently, three dimensional models even with tools stress analyses can be applied. The studies presented in this paper are the summaries of research work of forging of fasteners; which are either in design stage or in production with problems such as die filling or tool failure. Case studies are grouped into those sections: material flow, die filling and tool stress analysis. In the material flow section, it is shown that how powerful the FE simulation tool is on predicting the lap formations and buckling. Preform modification to cope with die underfilling is discussed in die filling section. Last part is related with elongation of tool life. All those studies yielded forging defect free products within short design times.