Computer Simulation of the Technology for Producing a Stamped Billet for the Piston of an Internal Combustion Engine of an Unmanned Aerial Vehicle

The technological process of hot-die forging billets for the piston of an internal combustion engine (ICE) of an unmanned aerial vehicle (UAV) made of AK4-1 aluminum alloy using the Deform-3D software package has been modeled. The object of simulation is a real ICE piston mounted on a Russian UAV. During modeling, the following parameters are introduced: the temperature of the tooling and the billet is 450°C, the ambient temperature is 20°C, the speed of the punch is taken as 5 mm/s, and the Siebel friction index is 0.4. A rigid plastic medium is chosen as the material model. The number of elements (6000) is assigned so that at least three of them fit in the narrowest section of the part. Thus, using the example of a stamped piston forging, it is shown that, using computer simulation in the Deform-3D program, it is possible to develop processes of hot-die forging of aluminum alloy billet for the manufacture of pistons for UAV ICEs. At the same time, computer modeling allows you to design a tool, evaluate the power parameters of the hot-die forging process, study the nature of the shape of the billet during die forging, and make the necessary adjustments to the virtual technological process that will make it possible to select the most optimal technical solutions when designing a real process. This computer-simulation technique can be extended to other stamped forgings from aluminum alloys.