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1	Development of Experimental and Finite Element Models to Show Size Effects in the Forming of Thin Sheet Metals Morris, Jeffrey D 05 August 2019 (has links) Abstract An experimental method was developed that demonstrated the size effects in forming thin sheet metals, and a finite element model was developed to predict the effects demonstrated by the experiment. A universal testing machine (UTM) was used to form aluminum and copper of varying thicknesses (less than 1mm) into a hemispherical dome. A stereolithography additive manufacturing technology was used to fabricate the punch and die from a UV curing resin. There was agreement between the experimental and numerical models. The results showed that geometric size effects were significant for both materials, and these effects increased as the thickness of the sheets decreased. The demonstration presents an inexpensive method of testing small-scale size effects in forming processes, which can be altered easily to produce different shapes and clearances. stereolithography punch/die geometric size effects hemispherical-cup-forming experiment aluminum and copper finite element model Computer-Aided Engineering and Design Engineering Science and Materials Manufacturing Materials Science and Engineering Mechanical Engineering Mechanics of Materials Other Materials Science and Engineering Polymer and Organic Materials