A new method to measure the frictional stresses and normal pressure in the roll gap during cold rolling, and experimental verification of this new method, are presented. The method overcomes many of the shortcomings of pin-type sensors. The elastic deformation of the roll itself is measured with strain gages, and is used to calculate the stresses between the sheet and the roll. Since no modification of the roll is necessary, the deformation process is undisturbed by the measurement. Mechanical isolation of the sensor is unnecessary. The mathematical procedure used to calculate the normal pressure and frictional stresses from the measured strains explicitly acknowledges that these strains are the result of the entire distribution of pressures and shears in the roll gap. An experimental rolling mill was constructed to verify the proposed method. Lead was rolled, and the resulting pressure and frictional stress distributions in the roll gap were measured. Several features of these distributions are in agreement with measurements made by various investigators using other techniques, thereby confirming the usefulness of the new method. Future work is proposed to increase the accuracy with which the roll gap stresses may be measured.

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