Abstract: The dynamic models and elasto-plastic finite element models of the non-plug and with-plug processes were established for the two-pass drawing process of an aluminium tube from circular to rectangular section,and then the simulation was performed.The results revealed that the drawing load touched bottom when the semi-die angle α2=11°.The sizing section of drawing die got optimized with angle β=178°,which eliminated instability.The residual stress waved along rectangle sides,and the maximal difference was 3.06 MPa.The spring-back strain also waved along rectangle sides,and the maximum was 0.000 7 and the minimum 0.000 1.The simulation results got good testing verifying.