TC16 titanium alloys have good mechanical properties and cold forming performance, widely used in the production field of aerospace fasteners. To study hexagon bolt heading behaviors of TC16 titanium alloy wire, hexagon bolt heading behaviors of TC16 titanium alloy wire was simulated by MSC.Marc finite element simulation software. The simulation results show that friction coefficient has great effects on the deformation degree and the temperature increasing distribution in different zone, initial temperature has little effect on the deformation degree but has greater effect on the temperature increasing in different zone. The mould can not be fully filled when friction coefficient is lower. However, prone flash will be produced when friction coefficient is higher. A better hexagonal head shape can be got when friction coefficient is 0.1. A good fit between simulation results and real testing can be found by contrasting the simulation results with real hexagonal head bolt microstructure and micro-hardness.