The cylindrical die forgings billet of titanium alloy was prepared by 10000 t hydraulic press, and based on Deform-3D software, the serious local folding and cracking problems occured in the forming process were simulated and analysed. Then, two solutions of billet structure optimization and forging fire increase were proposed, and the process verification was carried out. Furthermore, the mechanical properties at room temperature and high temperature of forgings were detected by tensile and impact samples, and the microstructure of forgings was analysed by optical microscope. The results show that during the die forging process of titanium alloy, the metal streamline, temperature field distribution and equivalent strain variables are abnormal, which resulting in the risk of folding and cracking in local positions of forgings. By optimizing the billet structure and increasing the forging fire, the distributions of metal streamline direction and temperature field in forging are effectively controlled to improve the forming limit of titanium alloy in local positions, avoid folding and cracking defects in the forming process and ensure the product quality, and the performances of product meet the requirements to improve the production efficiency.