The three-dimensional finite element method was utilized to investigate the isothermal forging of Ti46.5Al-2.5V-1.0Cr-0.3Ni (atomic percent, %) alloy. The partition of height reduction, effective strain, and damage of the alloy during the forging were analyzed. The simulation results were verified by experiments. The results show that large plastic deformation can improve the homogeneity of the deformed microstructure and the higher accumulative height reduction can be achieved through two-step forging. With the isothermal forging of two-step reduction of 60% + 62.5% (total height reduction of 85%), the entire forged pancake can acquire refined microstructure and expand the uniform flow zone to almost the entire volume.
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