Abstract In this work, the authors present an investigation on technological parameters affecting the flow forming process of aluminum alloy 6060 tubular structures and to discuss about the tools maintenance. Flow forming tests were carried out by mounting a single roller on a lathe machine. A 3D thermo-mechanical finite element model was developed to analyze the interaction between the roller and the workpiece in terms of forces, strains and thermal distribution. The effects of friction conditions were investigated through the FE model results and comparing them with acquired thermal maps. The model was validated by comparing the geometrical characteristics of the workpieces, such as the axial elongation, the inner and outer tube diameter. Aluminum spring-back was taken into account with material model adopted in the numerical algorithm. Once collected a complete information on the process parameters, some thermal images were acquired on roller in order to find a parameters set able to reduce the stresses acting on it as far as to obtain the maximum elongation with the minimum number of passes
