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The friction stir welding computational fluid dynamics (CFD) model in three dimensions (FSW) for quantitatively study to effect heat generation on the work piece material at different tool pin profile are revealed in this study. The simulated thermal parameter are studies and compare with experimental results. The FSW process is modeled the laminar flow and transient condition for various welding condition. The rotating tool geometry such as cylindrical, tapered, triangular and square are used for FSW. Analysis of the thermomechanical behavior of various pin profiles at spindle speeds of 1000 rpm and feed rates of 16–63 mm/min. The tapered tool pin profile is effective as compared to other tool pin because it generates maximum temperature and strain rate. The tapered pin profile has lower surface area and therefore gives better performance due to maximum heat generation of 695 K and high strain rate of 0.9 S−1 as compared to other. On the other hand, modelling results for the tapered pin profile reveal an increase in temperature of around 80% of the base materials' melting point. [ABSTRACT FROM AUTHOR]

The joints of aluminum alloy frames are usually welded by manual TIG welding. In order to study the distribution law of welding stress level and welding temperature field of intersecting joints of 6061-T6 aluminum alloy bicycle frames, a intersecting joints model of welding parts was established by Finite Element Model (FEM), Software. Based on ABAQUS software, the welding temperature field and welding stress field were studied and analyzed by using direct thermal coupling method. The accuracy of welding simulation is fully verified, which can meet the simulation requirements required for the subsequent optimization process design, and achieve the purpose of shortening the time required for the accumulation of practical inspection.