A method combining forging numerical simulation，BP neural network and SQP algorithm is developed to optimize the die cavity and reduce the wear of top die core，so as to improve die life. Optimal mathematical model is established for the purpose of equal wear and cubic spline interpolation curve is used to describe the shape of the forming part of top die core based on MATLAB. Then BP neural network is trained by the results of forging numerical simulation and modified Archard wear model to establish the relation between the control point of die cavity and the objective function. Finally，SQP algorithm is used to optimize the design variables and get the best shape of top die core. The results show that the wear of top die core decreases and becomes more uniform. The uniformity wear is reduced by 38.4% after optimization.