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Digital image correlation (DIC) is an increasingly popular and effective non-contact method for measuring full-field displacements and strains of deformable bodies under load. Current DIC methods applied to bodies undergoing large displacements and rotations require a large measurement area for both the reference (i.e., undeformed) image and the deformed images. This can limit the resulting resolution of the displacement and strain fields. To address this issue, we propose a two-stage dynamic DIC method capable of measuring displacements and strains under material convection with high resolution. During the first stage, the reference image is assembled from smaller, high-resolution images of the undeformed object obtained using a spatially-fixed or moving frame. Following capture, each sub-image is rigidly translated and rotated into its appropriate place, thereby producing a full, high-resolution image of the reference body. In stage two, images of the loaded and deformed body, again obtained using a small camera frame with high resolution, are aligned with matching regions of the undeformed composite image using BRISK feature detection before performing DIC.We demonstrate the method on a contact problem whereby an elastomeric roller travels along a rigid surface. In doing so, we obtain fine resolution measurements of the state of strain of the region of the roller sidewall in contact with the substrate, even as new material convects through the region of interest. We present these measurements as a series of images and videos capturing strain evolution as the roller transitions from static loads to a fully dynamic steady-state, documenting the effectiveness of the method. 

Elastomeric rollers are important components in applications such as printing and roll-to-roll manufacturing. To gain insight into roller mechanics and provide a basis for further investigations into dynamic rolling problems where rolling instabilities and rolling friction arise, we employ a specially designed apparatus to obtain displacement and strain fields via digital image correlation (DIC) under applied loads.We test loading scenarios leading to impending slip of an elastomeric roller, mounted on a steel hub, and in contact with a glass (rigid) substrate. We first examine strain fields under normal loading and compare them with the closest analytical predictions. We also analyze the strain fields under normal and tangential loading for which limited analytical predictions exist. For each loading scenario, we discuss the displacement and strain fields of the roller sidewall and contact interface. We implement a conceptual string model to demonstrate how stick and slip zones develop within the contact area as well as how memory effects arise during cyclic loading. This memory effect is then verified experimentally using the DIC strain fields. Additionally, we demonstrate a means for identifying the stick zone area between the roller and substrate using the experimentally-obtained displacement fields. We believe the apparatus, and the ability to obtain experimental displacement and strain fields, will prove valuable in understanding roller mechanics and associated instabilities. 

Instabilities that develop at the contact interface of solid rollers or airless tires while in motion can lead to increased energy losses and reduced service life. This manuscript describes an instrument that can give better insight into the origin of such instabilities by monitoring both local and global roller mechanics. This is done by simultaneously obtaining force and displacement data from sensors as well as optical measurements and local deformation fields across two different planes, extracted from images taken by a high-speed camera. Multiple loading configurations are possible, ranging from static normal loading of the roller to free rolling and rolling with a propulsive or a braking torque. Instrument functions, elements, and design are presented in detail and its capabilities are demonstrated by obtaining measurements such as width of the contact interface under normal loading, strain fields of the roller sidewall and contact interface under normal loading, and the roller’s resistance to motion for free and forced rolling.