Sheet metal forming is considered to be one of very important technological processes in manufacturing industries that a lot of research have been under taken to develop it further. The old used method involved a great deal of time and money in finding a appropriate tooling, geometry and manufacturing parameters by trial and error. The aim of most sheet metal forming research is to minimize the time and cost for processes development and production while minimizing scrap and optimizing the quality of the parts produced. Finite element analysis is considered by the researchers to be the key enabling technology for achieving these goals. The finite element simulation which can be used for predicting key outcomes of the forming processes such as the final shape of the part, flow of material, possibility of failure and amount of spring back. A finite element program using ABAQUS software has been developed for a cup drawing process to analyze the effect of different punch radiuses to the flow of material, cup wall shape and spring back. All the represented results shows a reduction of material at the cup wall with maximum reduction at the position of the die radius position. The punch radius needs to be selected in a range between not less than four times the billet thickness and less than 16 times the billet radius, there is not a lot of effect on the spring back only little effect on the thickness variation. Another finite element program has been developed for an extrusion process to analyze the effect of the material flow and compare it with the cup drawing process.