Difficult-to-deform titanium alloys are prone to have various forging defects during the forging production process, which seriously affects the production efficiency and the product quality. Firstly, the five typical forging defects such as cracking, coarse grain in the core, bright bands of fine grains, obvious deformation streamlines and Yin and Yang surfaces were described, then by tracing its production process and heating, forging, intermediate inspection and other related processes, the causes of forging defects were analyzed from multiple angles such as material properties, production process and other aspects by visual, metallographic examination and ultrasonic flaw inspection and so on. Finally, on this basis, the measures to solve and prevent the above-mentioned forging defects were proposed, and the relevant implementing effects were tracked and verified. The results show that the cause analysis of forging defects is reasonable, and the corrective and preventive measures are effective, which effectively promotes the continuous improvement of the forging level and product quality of difficult-to-deform titanium alloys.