Simulação e validação experimental do comportamento mecânico de soldas MAG: uma abordagem por elementos finitos

Abstract

This study aims to compare the tensile strength in MAG (Metal Active Gas) welding using computational simulations in SolidWorks Simulation [trade mark] software, validating the results with experimental tests. The methodology involved the fabrication of twelve test specimens in AISI 1020 carbon steel, welded with E 70S-6 wire and varying electrical current parameters (89 A to 116 A) and constant potential difference (18.9 V). Tensile tests were conducted according to the DIN EN ISO 68921 standard, measuring maximum stress, deformation, and elastic modulus. Simultaneously, computational simulations with structured meshes (fine, medium, and coarse) were performed to evaluate the influence of discretization on the results. Geometric data of the weld bead and the heat-affected zone, obtained via ImageJ [trade mark] software, served as input for the simulations. The experimental results indicated an average maximum stress of 412 MPa, while the simulations showed variations of 5% (fine mesh), 8% (medium mesh), and 16% (coarse mesh) compared to the real values. The fine mesh demonstrated greater accuracy but required 4.5 times more processing time than the coarse mesh. It was concluded that the choice of mesh should balance precision and computational efficiency: fine meshes are ideal for simple geometries, while medium meshes offer a good cost-benefit ratio for complex structures. The study validates the applicability of finite element simulations in predicting the mechanical strength of MAG welds, contributing to the optimization of industrial parameters.