The catalytic converter is used in the engine setup in order to meet the emission limits. Catalytic converter comprises of a monolith type substrate and housing for its connection with engine exhaust. Catalytic converter housing geometric parameters such as inlet cone angle, diameter, position of catalytic monolithic and the shape of the inlet cone are vital importance for achieving better flow efficiency in the exhaust system. These parameters also influence manufacturing process such as die design, material properties, etc. In this paper, finite element analysis simulation is performed for different inlet cone angles to understand its significance. Material considered for the simulation is Stainless Steel 304 with a sheet thickness is 1 mm and co-efficient of friction between the sheet and die material is 0.15. Nonlinear stress-strain curve for sheet material is determined through experimentation and the same is given as input for material property. Simulation results for different inlet cone angle have been evaluated using the Forming Limit Diagram. From investigation 600 inlet cone angle is identified as optimized process parameters in terms of manufacturing aspect. © 2019 Elsevier Ltd.