AbstractA numerical analysis program, based on slab analysis, was developed to calculate the stresses and strains that occur in the component layers of a composite sheet in the roll bite during the fabrication of clad metal (e.g. silver clad phosphor bronze) by roll bonding. Results calculated using the perfect plastic and strain hardening models were compared with experimental results: the results obtained using the strain hardening model were found to be in better agreement with values of rolling force and thickness of component layers measured after roll bonding. The program requires input data such as roll radius, initial thickness of the specimen, initial cladding thickness fraction, reduction ratio, coefficients of friction between rolls and material and between component layers, and front and back tensions. The coefficients of friction were evaluated indirectly by comparison of the measured rolling force with that calculated using slab analysis. Measured coefficients of friction varied with reduction ratio and initial thickness, but were independent of rolling speed.MST/1334