Abstract: The R-fluted square aluminium alloy tube and the manufacturing pocesses thereof are analyzed.As a result,it is identified that the currently-employed weld pipe forming processes have shortcomings in terms of making any type of the transformed fluted steel tube,no matter they feature either turning a round blank into a square one or directly forming a square blank.A new concept of an ideal process is described here in the paper,i.e.,with adopting both the cold-rolling process for section steel and the weld pipe forming process,firstly getting the strip steel rolled,and then,welded into an R-fluted round tube blank,and finally,transformed into an R-fluted square tube.Furthermore,addressing manufacture of the fluted weld tube,the design principle of “one-time formation” involving the simultaneously-rolling process,or one-time rolling process,and relevant design method and product qualification criteria are put forward.Thanks to the newly-developed manufacturing process,the R-fluted square steel tube with satisfactory appearance no second to that of the R-fluted aluminiun alloy square tube is successfully produced.The success will be beneficial to metal furniture makers in terms of material selection and operation cost-control.