An efficient and low-cost forming method was explored and studied aiming at solving the problems of low efficiency and poor dimensional accuracy in traditional stamping and welding process for aluminum alloy T–shaped tube used in aeronautical field. The design of flanging process and die development of 6061 aluminum alloy T–tube were carried out by the combination of finite element simulation and experiment. The effects of three different structures of drawing heads

conical

concave conical and spherical on the forming are simulated

respectively. Meanwhile

the influence was explored for the variation of wall thickness thinning ratio of branch tube under different initial pre-hole conditions. With the help of electronic universal testing machine

the flanging force under different pre-hole conditions was accurately recorded and compared. The results show that the designed die can realize the efficient forming of 6061 aluminum alloy T–tube with branch height of 3mm

and the maximum wall thickness thinning ratio is about 33.6%.