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In this paper, a new forward extrusion process is proposed for producing large-diameter tubular components. At the beginning of the process, a round billet is located in the container and then extruded into a preliminary die with three bean-shaped holes forcing a hole in the original billet. The material is then entered into another die with a diverging and converging surfaces designed to weld the material and decrease the tube thickness. Material flow behavior, applied strain and the required process load were predicted using finite element (FE) simulations. The results showed that the new extrusion process had three important advantageous namely a lower process load and a container with a smaller diameter while applying much higher plastic strain compared to the conventional methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .. . . . . . . . . .. . . .. . . . . . . .. . . . . . . .. . . . . . . . . . . . . . . . . . . .. . . . .. . . . . .. . . . . . . . . . . . . . . . . .

Keywords: Tube, Extrusion, experiments, FEM

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