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Vol. 32, No. 8(2), S&M2292

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Sensors and Materials, Volume 38, Number 6(2) (2026)
Copyright(C) MYU K.K.
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


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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.



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