Tube spinning or flow forming process is used for manufacturing of seamless tubes widely put into service in advanced industries. The ideal flow for materials entering the deformation zone in this process is extrusion-type flow in axial direction. Very localized deformation zone which is confined by outer materials and forming tools is very important aspect of this process. Therefore, development of defects during the deformation process with undesirable flow of materials can be easily occurred. The main reason of undesirable flow of materials is choosing inappropriate process parameters which results in arising various geometrical and dimensional defects. In this paper, the effects of process parameters on formation and growth of different defects and their correlations with material flow and forming forces in tube spinning of AA6061 was investigated by using design of experiment (DOE) method. The results of experiments show that by applying the optimized values of reduction and feed rate per revolution, these defects can be controlled. Also, by comparing the experimentally measured and theoretically calculated forming forces it can be shown that the larger the deviation of measured forces from calculated ones gets the more severe formation of defects and undesirable materials flow becomes.