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The study presents an analysis of the manufacturing process of a hollow forging. The process was proposed to consist of three stages. In the first stage (extrusion) wall thickness was reduced and the flange was formed. In the two subsequent stages the flange was formed. The material flow was examined using FEM. The issue of defect occurrence in the area of a hole caused by the material moving away from the mandrel was especially researched. Moreover, the strain state was analysed in the following forging operations. The distribution of the fracture criterion was presented. Moreover, a prediction of the forces necessary for the process to be performed in real conditions was carried out. The conclusion is that the proposed scheme of forming hollow forgings may be implemented in industrial conditions.

FEM analysis of the manufacturing of hollow forgings from a tube billet