The forging process of aluminum alloy U-shaped arm is complicated and the flow process is long, then the stepped long-axis billet after cross wedge rolling is prone to instability, folding and poor shape and dimension accuracy when bending. Therefore, for the automobile aluminum alloy U-shaped arm, its product characteristics and forming process scheme were analyzed. Then, the finite element numerical simulation of bending process was carried out by using software Deform, and the folding defects were predicted and the causes of defects were analyzed. Furthermore, a new multi-direction bending process was proposed. The results show that the forgings subjected to multi-directional bending has uniform deformation and no folding defects, the head is lateral flattened, and the pre-forging and final forging filling effect are good. Based on the existing automatic forging production line for aluminum alloy precision forging, the experimental verification is conducted, and the final aluminum alloy U-shaped arm forgings are well filled with high surface quality, which is consistent with the simulation results. The research results indicate that the multi-directional bending process can improve product quality and material utilization rate.