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This paper presents results on the effect of aspect ratio on the flow stress of 42CrMo4 steel using Deform™ 3D Version 11 simulation software. The FEM simulation process conditions were upsetting temperature of 1000 °C and 10 s⁻¹ strain rate. The sample aspect ratios (height/diameter) varied within commonly used ranges during conventional Gleeble experimentations. The aspect ratio did not affect the flow stress behaviour during forming. Generally, the forming conditions influence the flow stress-strain field and distribution behaviour, causing inhomogeneous deformation. A negligible effect of aspect ratio on typical industrial forging process is only attainable between 1.0 and 2.0. The implications of the results for industrial forging are elucidated.