Data-Driven Prediction of Stress Field in Additive Manufacturing Based on Deposition Layer Shrinkage Behavior

This study proposes a stress field data-driven prediction method that combines a finite element thermo-mechanical coupling model with a multi-machine learning framework. This method takes the inversion of stress based on the shrinkage behavior of deposition layers as the core logic, extracts the node displacement shrinkage during the cooling to solidification process of the melt pool in the thermal coupling simulation as the key feature input, and constructs extreme gradient boosting (XGBoost), Gaussian process regression (GPR), and deep convolutional neural network (DCNN) models, respectively, to achieve accurate prediction of nodal effect stress and triaxial stress in the laser directed energy deposition (L-DED) node process. The experimental results show that the XGBoost algorithm performs the best in various stress prediction indicators, and its generated stress distribution cloud map is highly consistent with the thermal coupling simulation results, suggesting a strong correlation between deposition layer shrinkage behavior and the stress field under the investigated conditions. In addition, compared to traditional finite element simulations, this method significantly improves computational efficiency while ensuring prediction accuracy, providing a new approach for rapid assessment of residual stresses.