Treffer: OS-WeldSim: an open-source framework for finite element-based welding simulation.

This research introduces a novel framework for welding simulation as a cost-effective alternative to finite element-based software. The proposed framework integrates several open-source tools, including FreeCAD, CalculiX, PrePoMax, and ParaView. Mesh generation can be performed using either open-source software or freely accessible tools such as PrePoMax or Coreform Cubit. Additionally, an optional post-processing step employing the commercial software Kotem Smart Profile is included to enhance the engineering analysis and support a comprehensive, end-to-end welding simulation workflow. In this approach, a 3D model of the weldment—including welding plates, clamps, and weld beads—is first created using FreeCAD. We developed an add-on for trajectory definition. We integrated PrePoMax or Coreform Cubit add-on to generate the required finite element mesh, define boundary conditions, and format the input file for the finite element solver. Coreform Cubit is available in a limited-capability free version (e.g., student edition), whereas PrePoMax is a fully open-source software. Welding simulation is then performed using CalculiX with the shrinkage method. The computed welding deformations are processed by the Coreform Cubit add-on or PrePoMax / ccx2paraview python library to generate a ParaView-readable format, which is used for visualization. Finally, ParaView outputs, along with engineering drawings, are analyzed using Kotem Smart Profile for GD&T-based engineering post-processing. To validate the framework, we compared the shrinkage method implemented in CalculiX with the inherent strain method and advanced thermal cycle method used in commercial software packages. The results demonstrate that our open-source framework provides an accuracy comparable to commercial solutions. Given the high cost of commercial software, which limits accessibility for academic institutions and small- to medium-sized industries, this framework offers a viable and affordable alternative. Additionally, we provide a comprehensive manual, repositories to guide users in implementing welding simulations with open-source tools. [ABSTRACT FROM AUTHOR]

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