In the temperature analysis of hot metal forming process, the heat transfer conditions between the work-piece and the tool have improtant influences upon the temperature distribution. The accuracy of thermal analysis depends on the proper description of boundary conditions including heat transfer. At the contact surface of two materials with different temperatures, this requires the knowledge of the overall heat transfer coefficient. In order to determine the overall heat transfer coefficient, a technique is developed. The technique involves temperature measurement by using thermocouples during hot upsetting operations and finite element computation. The overall heat transfer coefficient is determined using a non-linear optimization technique.