Due to the structural of forgings, the TB6 titanium alloy main rotor hub is prone to produce a large area of “deformation dead zone” at its upper and lower end faces. Therefore, for the main rotor hub of a certain type of helicopter, a pre-forging structure design was used for improving the deformation step to optimize the forming process. The strain distribution, temperature distribution, metal streamline distribution, dynamic recrystallization fraction of β phase, average grain size of β phase and average grain size of α phase for the pre-forging and final forging processes that had a great influence on the structure uniformity degree of forgings were predicted and analyzed by numerical simulation software Simufact. At the same time, the trial forgings were conducted based on the simulation result. The results show that the forming process with the pre-forging structure design of main rotor hub is reasonable and feasible. The deformation of the whole pre-forging process is uniform, the average grain size of α phase at the upper and lower end faces decreases continuously, the average grain size of α phase at edges increases, the distribution of metal streamline is reasonable, and the forming effect of the pre-forging blank is good. The overall deformation in the final forging process is relatively uniform, the average grain size of α phase is between 2.64-4.90 μm which makes a good size match with the matrix β phase, the metal streamline distribution is reasonable, and the forming effect of forgings is good. The trial TB6 titanium alloy main rotor hub forgings have little difference and good uniformity in microstructure and properties.