This paper presents the research results of hammer forging process of a plane wheel rim forging from titanium alloy Ti6Al4V. The research works were divided into two stages. The first concerned the theoretical analysis based on numerical simulations of the worked out forging technology. Distributions of temperature, strain, damage criterion according to Cockroft-Latham, material flow kinematics and force parameters were evaluated. It was stated that the danger of overheating and material cracking in the forging does not exist. Large force values present in the process means that problems with tools durability may appear. Satisfactory results of the theoretical analysis provided the basis for conducting the second stage of the research works, that is experimental tests in industrial conditions. After dies making forging tests were made in one Polish forging plants, in which a product of good quality was obtained. Manufactured forgings were free from cracks, shape faults and fulfilled requirements concerning mechanical properties.