In this paper, a new cold bending process is presented to form the titanium alloy tubular part with small relative bend radius, that is, its centerline bending radius is less than 2 times the outside diameter of the tube. FEM is applied to simulate the forming process, and at the same time the results, such as the distribution of the stress and the wall thickness, prediction of defects area, the effects of the internal pressure and friction condition on the tube deformation, are also analyzed. Finally, experimental research was preformed. It is found that the numerical results are in good agreement with the experimental values.