In this study, an optimized forging process for assembling hub bearing assembly is proposed. The shape of initial material is optimized to minimize forging load. The outer shape of inner race of the bearing is also improved not only to minimize forging load but also to reduce the total weight of the hub bearing assembly. The initial material with the inner race for rotary forging needs about 140 tons to be forged while the proposed design needs about 70 tons to be forged.