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pp. 3125-3132
S&M4492 Research paper https://doi.org/10.18494/SAM6225 Published: June 12, 2026 Predicting Springback via a Stress-based Indicator [PDF] Cheng-Kai ChiuHuang and Tsung-Cho Wu (Received January 23, 2026; Accepted April 24, 2026) Keywords: 7075 aluminum alloy, warm forming, hot forming, springback, stress differential
We present a stress-based indicator for predicting and evaluating the springback behavior of 7075 high-strength aluminum alloy during warm (150 and 250 °C) and hot (490 °C) forming through experiments and numerical simulations. The results indicate that while hot forming yields the minimum springback, the springback angles in warm forming are notably higher and exhibit a decreasing trend as the forming temperature increases. To clarify this behavior, the total absolute stress differential (Stotal) is introduced to quantify the through-thickness stress imbalance. By integrating the numerical model with press equipment parameters including blank holder forces and positions, the Stotal indicator can be used as a computational sensor for monitoring internal stress states. The findings suggest that the reduction in springback at higher temperatures is driven by a marked decrease in the accumulated stress differential, demonstrating a clear positive correlation between these two physical quantities. This work provides a robust mechanical basis for the potential real-time adjustment of forming conditions, facilitating the intelligent quality control of high-strength aluminum alloys at elevated temperatures.
Corresponding author: Cheng-Kai ChiuHuang![]() ![]() This work is licensed under a Creative Commons Attribution 4.0 International License. Cite this article Cheng-Kai ChiuHuang and Tsung-Cho Wu, Predicting Springback via a Stress-based Indicator, Sens. Mater., Vol. 38, No. 6, 2026, p. 3125-3132. |