A fast matrix-free elasto-plastic solver for predicting residual stresses in additive manufacturing

Process planning for additive manufacturing (AM) today relies heavily on multi-physics, multi-scale simulation. The focus of this paper is on one aspect of AM simulation, namely, part-level elasto-plastic simulation for residual stress and distortion predictions. This is one of the crucial steps in AM process optimization, but is computationally expensive, often requiring the use of large computer clusters.