Abstract
Tool profile plays a key role in the Friction Stir Welding (FSW) process to generate friction and its failure in working conditionslead to heavy losses. Hence in this work, a method has been proposed to choose a suitable tool profile. For this purpose, various tool profiles have been modelled using Solid works 16 and analysis was done using ANSYS 15.0. Structural and Thermal simulations have been carried out in this work. Structural analysis was done only to prove that the tool withstands the working conditions without failure. The main scope of this work is the thermal analysis as it defines how to select a tool profile.It was found that among all the six tool profiles analyzed, tool pin with the triangular profile emerged as the best profile with low heat flux.
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