Gas Metal Arc Welding (GMAW) is widely adopted in automated manufacturing industries where the accurate prediction of thermal fields and welding-induced distortions is essential to ensure joint integrity of the parts; however, finite element modeling, as the most reliable non-destructive predictive approach, remains time-consuming and highly user-specialized. This work presents an automated and low computational cost thermo-mechanical finite element methodology implemented in Ansys Parametric Design Language (APDL) for the parametric analysis of GMAW T-joints, integrating automated geometry generation, meshing, heat source implementation, and thermo-mechanical modeling for different beam and weld seam dimensions under continuous or intermittent single-pass configurations. A volume element selection strategy is introduced to limit heat input calculations to the active weld pool region, achieving up to a 50% computational time reduction while maintaining high predictive accuracy, in contrast with conventional and partial selection methods. Overall script performance was validated through temperature and displacement comparisons between the numerical and experimental results of two T-joint configurations using SM490A structural steel specimens. The results demonstrate that the developed macro provides a useful tool for automated thermo-mechanical welding analysis, significantly reducing model preparation effort while enabling the evaluation of parametric T-joint geometries and welding conditions with a low computational cost focus.

The tube-notching process is widely used to manufacture structural joints and ducting systems for fluid transport. In these applications, accurate intersection angles and proper fit-up geometry are essential to ensure reliable assembly and system performance. Consequently, CNC-based automation is increasingly adopted to improve productivity in operations where precision and cycle time are critical. The main problem, however, lies in the complexity of generating accurate cutting trajectories for tube–tube intersections and converting them into machine-executable commands. This study addresses this gap by proposing a simple, novel mathematical model for toolpath generation capable of producing intersection profiles at arbitrary joint angles, including lateral offset (non-coaxial) configurations. A systematic procedure was developed to convert the resulting trajectories into G-code, which was processed in a low-cost CNC plasma cutter designed to experimentally validate the toolpaths. The machine incorporates a fourth axis to enable bevel cutting during tube processing. Experimental results demonstrate stable operation, high dimensional accuracy (error ±0.1°), and consistent cut quality for trajectories generated by the proposed model, confirming the feasibility of the low-cost CNC plasma system and its scalability to diverse fabrication requirements.