The pipe die forging with solid-medium-filling was simulated by finite element method to the effects of parameters

such as blank size

core volume and friction coefficients

on the thickness distribution and shape accuracy. The stress–strain cures of tube blank material and core material were obtained by unidirectional tensile test and unidirectional compression test. The methods of determining the geometric dimensions of tube blank and core based on the final parts were given. The tangential parting surface was proposed in die design in order to avoid flash. According to the material data

the geometric model of tube blank

core and die

the finite elemen

t model of forming process was established. Then the processing was simulated. Taking the part thickness distribution and the gap between part and die in the simulation results as the indexes to evaluate the forming quality

the effects of the dimensional parameters of α and β and the friction coefficients f

i

and f

t

on the forming results are analyzed. The results show that the dimensional parameter combination α=1.00 and β=1.05 and the friction coefficient combination f

i

= 0.05 and f

t

= 0.05 are more conducive to the thickness distribution and shape accuracy.