<p>This study systematically analysed and optimised the hot-forging process of wheel rims made of aluminium 6061 alloy, with the objective being to achieve the desired rim shape, dimensions, grain refinement, and strength. First, friction coefficients were determined through the hot ring compression test, and the displacement and load variations of specimens were analysed at temperatures of 200&#xa0;°C, 300&#xa0;°C, and 450&#xa0;°C to calculate plastic flow stress. The data obtained in these steps were then applied in finite-element simulations of aluminium alloy rims to predict the influence of forging load, die stress, temperature, and forming speed on formability and product quality. This study thoroughly investigated the effects of friction on rim formation under various billet aspect ratios, forging speeds, and temperatures. Die design and manufacturing were conducted using optimal forming parameters, and hot-forging experiments were performed using graphite as a lubricant to assess the effects of forming temperature and load curves on product dimensions and forging force. A comparison between experimental and simulation results indicated a high degree of accuracy in predicting product dimensions; thus, the adopted simulation method can be employed for process design and equipment selection. Finally, metallographic observations and hardness tests were conducted to analyse grain structure and hardness distribution across different regions of the fabricated rims; these steps allowed examination of the effectiveness of the obtained optimised forging parameters in enhancing formability and quality. The results of this study serve as a reference for advancing hot-forging techniques for aluminium alloy wheel rims.</p>