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The selected issue of flange cracking in the radial extrusion process of hollow parts has been discussed in this
paper. The researches were carried out based on numerical calculations in the Deform 3D software and experi-
mental tests, which were carried out using pipe billets made of aluminum alloy EN AW 6063. A new methodology
has been developed that allows to determine the place and approximate moment of material cohesion loss. This
is determined from the results of the FEM calculation only, and does not require calibration tests. The method is
based on a detailed analysis of the state of stress, state of strain in the extruded part, and is focused on identifying
zones with an uneven distribution of the mentioned parameters. Determination of characteristic zones with a zero
increase in the strain effective value makes it possible to determine, with a high approximation, the maximum
(due to the phenomenon of cracking) diameter of the flange. The results of numerical calculations showed a high
agreement with the results of experimental tests, in which the maximum diameter of the flange was determined.
