Abstract: To improve the magnitude and distribution of residual stresses in TC4 titanium alloy forgings after solution and aging, thereby further improving the subsequent processing quality and service performance of the forgings, a numerical model for post-forging solution and aging was established, and the experiment was verified. Then, the residual stresses in forgings under different solution temperatures, solution time, aging temperatures, and aging time were analyzed through numerical simulations. Finally, the orthogonal experimental design and range analysis method were employed to determine the significance of influence of various process parameters on the residual stresses in forgings, and the optimal set of process parameters was identified. The results indicate that an increase in solution temperature, aging temperature and aging time can significantly reduce residual stresses at the center of the forging. Additionally, the influence of solution temperature on residual stresses is most significant, followed by aging time, aging temperature and solution time. The minimum residual stresses in the forging are achieved at a solution temperature of 900 ℃, solution time of 80 min, aging temperature of 500 ℃and aging time of 8 h, providing a rational basis for production practice.