Residual Stress Estimation in Structures Composed of One-Dimensional Elements via Total Potential Energy Minimization Using Evolutionary Algorithms

This study introduces a novel energy-based inverse method for estimating residual stresses in structures composed of one-dimensional elements undergoing elastic–plastic deformation. The problem is reformulated as a global optimization task governed by the principle of minimum total potential energy. Rather than solving equilibrium equations directly, the internal stress distribution is inferred by minimizing the structure’s total potential energy using a real-coded genetic algorithm. This approach avoids gradient-based solvers, matrix assembly, and incremental loading, making it suitable for nonlinear and history-dependent systems. Plastic deformation is encoded through element-wise stress-free lengths, and a dynamic fitness exponent strategy adaptively controls selection pressure during the evolutionary process. The method is validated on single- and multi-bar truss structures under axial tensile loading, using a bilinear elastoplastic material model. The results are benchmarked against nonlinear finite element simulations and analytical calculations, demonstrating excellent predictive capability with stress errors typically below 1%. In multi-material systems, the technique accurately reconstructs tensile and compressive residual stresses arising from elastic–plastic mismatch using only post-load geometry. These results demonstrate the method’s robustness and accuracy, offering a fully non-incremental, variational alternative to traditional inverse approaches. Its flexibility and computational efficiency make it a promising tool for residual stress estimation in complex structural applications involving plasticity and material heterogeneity.