In metal forming processes, the forging load as well as the mechanical and geometrical properties of the final product are affected by the actual material flow. Especially for incremental open die forming processes like rotary swaging, the material flow is very complex. By a profound knowledge about how to control this material flow during the process, the final product properties can be controlled. By using FEM, the material flow during infeed rotary swaging of tubes without mandrel was investigated by the history of the plastic strain components (PE_i) in different directions. The influence of the friction coefficient value on the material flow for steel tubes was studied. By the history of plastic strain components tracked during the process, the material flow was analyzed in different radial positions. Based on that, the influence of friction conditions on PE_i was discussed during one single stroke. It was found that with an increasing friction coefficient value, the radial plastic strain firstly increased and then decreased, while the axial plastic strain behaved just the other way round. Thus, the material flow is significantly affected by friction conditions. The simulation results were validated by measurements of wall thickness values of physically formed tubes.
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