In this paper a finite element based system is presented for the prediction of the distributions of the recrystallized grain sizes in the workpiece in hot forging. The system adopts a fully coupled finite element thermo-mechanical model for predicting plastic deformation and heat transfer occurring in the workpiece and employs existing metallurgical models relating the recrystalliza-tion behavior with the thermo-mechanical variables such as temperatures strain and strain rate. The system is applied to upsetting of cylindrical preform. The predicted grain sizes are compared with the measurements. It is further applied to forging of a complex-shaped product.