Abstract: Using the finite element analysis method coupled with the thermo-mechanical effect, the welding parameters (friction torque, axial shorting and average temperature), physical parameter fields(temperature filed, stress filed and strain filed), grain size of friction weld and their variations during whole friction welding process are simulated directly from the properties of the welded material and the input welding pa-rameters (axial pressure, rotate speed vs. time). The different generated heat mechanisms, the variable thermal properties of the material, the flash shaping and the variety of friction coeffi-cient with speed, temperature and pressure are especially con-sidered. This method could be used to forecast the welding parameters firsthand.

Key words: Finite element analysis, Friction welding, Thermo-mechanical coupled