The next generation of diesel engine can operate at high injection pressure up to 1,800bar. The common rail pipe must have higher internal strength because it is directly influenced by the high-pressure fuel. Folding defects in the Common rail pipe can not ensure the structural safety. Therefore, Preform design and fatigue-life analysis are very important for preventing the head of the common rail pipe from folding in the heading process and for predicting fatigue life according to the amount of folding. In this study, a closed form equation to predict fatigue life was suggested by Goodman theory and pressure vessels theory in ASME Code in order to develop an optimization technique of the heading process and verified its reliability through fatigue-structural coupled field analysis. The results calculated by the theory were in good agreement with those obtained by the finite element analysis.