Recently, physical simulation has played a more and more important role in modeling hot
forming process. However, difficulty still existed in simulating real hot forming process using
physical simulation results directly for obvious difference in deformation history between physical
simulation condition and real hot forming process. In this work, difference between physical
simulation and real hot forming process was discussed and a mathmatical approach was proposed to
model real hot forming process using physical simulation results. The main consideration of the
method was to put physical simulation results into differential forms in order to take count in the
contribution of deformation history (temperature and strain rate) at each incremental step. For the
application of the approach, modeling of material flow stress, dynamical recrystallization including
critical condition and recrystallziaton fraction, damage evolution and fracture criteria during real hot
forming process were presented as examples, although experimental support was still needed for
validation and further application.