Numerical Analysis of the New Forming Process of the Aircraft Bracket Forging Made of AZ91 Alloy at Different Rates of Deformation

The article presents the results of numerical simulations of the new forging process of the aircraft bracket forging at different deformation rates related to the type of machine used: a hydraulic press, a screw press and a drop forging hammer.The billet of shaped preforms from AZ91 alloy with two different geometries was used for the process.It was assumed that forging a bracket from an unformed, shaped preform will have a positive effect on the kinematics of the flow and on the deformation capability of AZ91 magnesium alloy, and will reduce the number of operations necessary to obtain the correct item.The numerical analysis of the new process was carried out with FEM, using the software Deform 3D.Based on the simulation, the important information about the process was obtained, that is the distribution of stress, deformation, temperatures, cracking and force parameters.The obtained results of numerical tests confirmed the possibility of producing the correct aircraft brackets forgings from AZ91 magnesium alloys with the proposed technology.