SPR (Self-Piercing rivet) is joining method that piercs sheets and join it at once. In this study, the forging process was designed for manufacturing new rivet. It can be predicted for high joining strength and shearing strength than existing rivet. Rivets are produced by cold forging process. but, there are limitations in experimental method. In the Process design, It is necessary to consider many things such as selection of the proper work process, work order, the number of processes, Process design technique and a selection of the machining equipment. And interpretive research is needed. It is possible to simulate by using various boundary condition in analytical method. In addition, FEM (finite element method) can reduce the cost and time of production by preventing loss of power. In this thesis, a new SPR forging design and forging are presented. The forging process by considering the shape of the rivets is determined. New SPR is designed by using Pro/ENGINEER and simulatated by commercial FEM code DEFORM-3D. Modifing the shape of the mold, the simulations have been repeated. Experimental results and the simulation results were compared and analyzed.