Abstract: In order to reduce the error between simulation results and actual forging,it is necessary to establish a more accurate finite element analysis model. On the basis of measuring the residual stress of forgings by X ray diffraction method,the forging deformation of TC4 titanium alloy and the unloading process of forgings were simulated by Deform-3D finite element software. The error between the test results and the simulation results was analyzed, and more accurate parameters such as boundary conditions were obtained. The finite element analysis model was modified and simulated by the modified model. The deformation law, residual stress distribution law and stress release law of TC4 forgings after unloading were revealed, which can provide reference for similar research.