finite element modeling and experimental study of the spline tube forming

metal forming processes, compared with machining ones, reduce production steps and increasemanufacturing speed in addition to saving raw material. in this paper, forming process of column ofa steering mechanism is investigated by finite element analyses and experimental tests; andoptimum die design parameters are found. forming process parameters including die opening angle,bearing length, clearance between work piece, die and friction coefficient were studied. some newideas were also used in manufacturing process of dies with compression tube forming process.without using an appropriate lubricant, friction coefficient between die, tube, the probability of tubedistortion and tube bulging increased significantly. the forming force is also strictly dependent onfriction coefficient and it also increases with increasing bearing length of the die. the manufacturedsample had good agreement with the original drawing of profile appearance and dimensions. effectsof die and tube clearance on the required force and final part surface quality are also investigated.