Browsing by Author "Shore, Paul"
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Item Open Access 3D characterisation of tool wear whilst diamond turning silicon(Elsevier Science B.V., Amsterdam., 2006-07-24T00:00:00Z) Durazo-Cardenas, Isidro; Shore, Paul; Luo, X.; Jacklin, T.; Impey, Susan A.; Cox, A.Nanometrically smooth infrared silicon optics can be manufactured by the diamond turning process. Due to its relatively low density, silicon is an ideal optical material for weight sensitive infrared (IR) applications. However, rapid diamond tool edge degradation and the effect on the achieved surface have prevented significant exploitation. With the aim of developing a process model to optimise the diamond turning of silicon optics, a series of experimental trials were devised using two ultra-precision diamond turning machines. Single crystal silicon specimens (1 1 1) were repeatedly machined using diamond tools of the same specification until the onset of surface brittle fracture. Two cutting fluids were tested. The cutting forces were monitored and the wear morphology of the tool edge was studied by scanning electron microscopy (SEM). The most significant result showed the performance of one particular tool was consistently superior when compared with other diamond tools of the same specification. This remarkable tool performance resulted in doubling the cutting distance exhibited by the other diamond tools. Another significant result was associated with coolant type. In all cases, tool life was prolonged by as much as 300% by using a specific fluid type. Further testing led to the development of a novel method for assessing the progression of diamond tool wear. In this technique, the diamond tools gradual recession profile is measured by performing a series of plunging cuts. Tool shape changes used in conjunction with flank wear SEM measurements enable the calculation of the volumetric tool wear rate.Item Open Access An accelerometer based-feedback technique for improving dynamic performance of a machine tool(European Society for Precision Engineering and Nanotechnology, 2016-06-30) Abir, Jonathan; Morantz, Paul; Longo, Stefano; Shore, PaulA novel concept for improving machine dynamic performance was developed and realised, a virtual metrology frame, for a small size CNC machine with flexible frame. Its implementation in a simplified linear motion system shows a reduction in the magnitude of the first resonance in the plant frequency response function by 12 dB. Realising the concept required developing a real -time accelerometer-based measurement technique. It shows a low sensor noise σ=30 nm with optimal phase delay of <70 μs.Item Open Access Active magnetic bearing for ultra precision flexible electronics production system(Cranfield University, 2015-12) Tantau, Mathias; Shore, Paul; Morantz, PaulRoll-to-roll printing on continuous plastic films could enable the production of flexible electronics at high speed and low cost, but the granularity of feature sizes is limited by the system accuracy. Technologies such as gravure printing and nanoimprint lithography demand a level of rotary motion precision that cannot be achieved with rolling element bearings. Manufacturing tolerances of the rotating parts, thermal drift and process forces in combination with structural compliance add up to additional error motions. In this master by research an active magnetic bearing (AMB) solution is designed for a new, super-sized roll-to-roll flexible electronics production machine, which was so far based on hydrostatic bearings. The magnetic bearing could actively compensate the accumulated synchronous error and maintain high accuracy under all conditions. However, the asynchronous error of a conventional AMB with the required size and power is a problem. In order to reduce the relatively high positioning uncertainty of active magnetic bearings an innovative radial position measurement based on linear, incremental encoders with optical conversion principle is proposed. A commercial encoder scanning head faces a round scale with concentric, coplanar lines on its face. By counting these lines the radial position can be measured. Because such a scale is not readily available, it is made by micro-machining. In experiments, different machining methods are compared. Then a magnetic bearing is built to demonstrate the efficacy of the proposed sensor. As a result, the best measurement noise is 3.5nm at 10kHz and a position uncertainty of approximately 0.25µm has been achieved for the magnetic bearing. These promising results are especially interesting for applications with high precision requirements at low speed of rotation.Item Open Access Advanced Bearing System for Ultra Precision Plastic Electronics Production Systems(Cranfield University, 2014-09) Zhao, Gang; Shore, Paul; Morantz, PaulThe aims of this MSc research project are to investigate the application of aluminium for the main components of an ultra-precision spindle defined for use in R2R production systems and to produce a reel to reel rotary aluminium hydrostatic bearing system of high accuracy to meet the demand of manufacturing the flexible displays with an effective production capability for this special kind of film-based product. The original concept design was already finished to manufacture the bearing components and the objective of this project was to test the functionality of this new hydrostatic bearing system. Firstly, theoretical were performed to work out the output responses, including temperature rise, flow rate, load capacity etc., of the hydrostatic bearing system under different input design parameters, including supply pressure, fluid viscosity, the rotational speed etc. Then ANSYS software was used to build a FEA model to simulate the actual working conditions of the hydrostatic bearing system and to obtain the theoretical output parameters, especially the deflection conditions of the bearing shaft. Finally the experimental validation tests were conducted to verify the actual output responses to check correlation with the modelled results.Item Open Access Analysis of De-Laval nozzle designs employed for plasma figuring of surfaces(Springer, 2016-02-27) Yu, Nan; Jourdain, Renaud; Gourma, Mustapha; Shore, PaulPlasma figuring is a dwell time fabrication process that uses a locally delivered chemical reaction through means of an inductively coupled plasma (ICP) torch to correct surface figure errors. This paper presents two investigations for a high temperature jet (5000 K) that is used in the context of the plasma figuring process. Firstly, an investigation focuses on the aerodynamic properties of this jet that streamed through the plasma torch De-Laval nozzle and impinged optical surfaces. Secondly, the work highlights quantitatively the effects of changing the distance between the processed surface and nozzle outlet. In both investigations, results of numerical models and experiments were correlated. The authors’ modelling approach is based on computational fluid dynamics (CFD). The model is specifically created for this harsh environment. Designated areas of interests in the model domain are the nozzle convergent-divergent and the impinged substrate regions. Strong correlations are highlighted between the gas flow velocity near the surface and material removal footprint profiles. In conclusion, the CFD model supports the optimization of an ICP torch design to fulfil the demand for the correction of ultra-precision surfaces.Item Open Access Analysis of nozzle design used for the creation of advanced energy beam(American Society for Precision Engineering (ASPE), 2014-11-14) Yu, Nan; Jourdain, Renaud; Gourma, Mustapha; Shore, PaulA variety of scientific and industrial projects, such as segmented ground based telescopes, compact space based observers, short wavelength microlithography and high power laser systems, demand metre scale ultra-precise surfaces [1]. Cranfield University and Loxham Precision have been engaged in developing effective fabrication of medium to large optical surfaces for the aforementioned applications. A process chain of three sequential machining steps has been proposed (Figure 1). These steps are ultra-precision grinding, robot based polishing and plasma figuring. The fabrication target is to reach a 20 hours cycle time for each stage of surface generation for 1.5m size optics: equating to 1ft2 per hour [2-3].Item Open Access Application of probabilistic modelling for the uncertainty evaluation of alignment measurements of large accelerator magnets assemblies(IOP, 2018-03-15) Doytchinov, Iordan; Tonnellier, Xavier; Shore, Paul; Nicquevert, Bertrand; Modena, Michele; Mainaud-Durand, HélèneMicrometric assembly and alignment requirements for future particle accelerators, and especially large assemblies, create the need for accurate uncertainty budgeting of alignment measurements. Measurements and uncertainties have to be accurately stated and traceable, to international standards, for metre-long sized assemblies, in the range of tens of µm. Indeed, these hundreds of assemblies will be produced and measured by several suppliers around the world, and will have to be integrated into a single machine. As part of the PACMAN project at CERN, we proposed and studied a practical application of probabilistic modelling of task-specific alignment uncertainty by applying a simulation by constraints calibration method. Using this method, we calibrated our measurement model using available data from ISO standardised tests (10360 series) for the metrology equipment. We combined this model with reference measurements and analysis of the measured data to quantify the actual specific uncertainty of each alignment measurement procedure. Our methodology was successfully validated against a calibrated and traceable 3D artefact as part of an international inter-laboratory study. The validated models were used to study the expected alignment uncertainty and important sensitivity factors in measuring the shortest and longest of the compact linear collider study assemblies, 0.54 m and 2.1 m respectively. In both cases, the laboratory alignment uncertainty was within the targeted uncertainty budget of 12 µm (68% confidence level). It was found that the remaining uncertainty budget for any additional alignment error compensations, such as the thermal drift error due to variation in machine operation heat load conditions, must be within 8.9 µm and 9.8 µm (68% confidence level) respectively.Item Open Access A basis for the representation, manufacturing tool path generation and scanning measurement of smooth freeform surfaces(2017-02) Morantz, Paul; Shore, PaulFreeform surfaces find wide application, particularly in optics, from unique single-surface science programmes to mobile phone lenses manufactured in billions. This thesis presents research into the mathematical and algorithmic basis for the generation and measurement of smooth freeform surfaces. Two globally significant cases are reported: 1) research in this thesis created prototype segments for the world’s largest telescope; 2) research in this thesis made surfaces underpinning the redefinition of one of the seven SI base units – the kelvin - and also what will be the newly (and permanently) defined value for the Boltzmann constant. Theresearchdemonstratestwounderlyingphilosophiesofprecisionengineering, the critical roles of determinism and of precision measurement in precise manufacturing. The thesis presents methods, and reports their implementation, for the manufacture of freeform surfaces through a comprehensive strategy for tool path generation using minimum axis-count ultra-precision machine tools. In the context of freeform surface machining, the advantages of deterministic motion performance of three-axis machines are brought to bear through a novel treatment of the mathematics of variable contact point geometry. This is applied to ultra-precision diamond turning and ultra-precision large optics grinding with the Cranfield Box machine. New techniques in freeform surface representation, tool path generation, freeform tool shape representation and error compensation are presented. A comprehensive technique for very high spatial resolution CMM areal scanning of freeform surfaces is presented, with a new treatment of contact error removal, achieving interferometer-equivalent surface representation, with 1,000,000+ points and sub-200 nm rms noise without the use of any low-pass filtering.Item Open Access Case study: meeting the demand for skilled precision engineers(Emerald Group Publishing Limited, 2008-01-01T00:00:00Z) Sansom, Christopher L.; Shore, PaulThis paper aims to demonstrate how science and engineering graduates can be recruited and trained to Masters level in precision engineering as an aid to reducing the skills shortage of mechanical engineers in UK industry.Item Open Access CFD analysis of an enhanced nozzle designed for plasma figuring of large optical surfaces(European Society for Precision Engineering and Nanotechnology, 2016-06-30) Yu, Nan; Jourdain, Renaud; Gourma, Mustapha; Shore, PaulFor addressing the correction of Mid Spatial Frequency (MSF) errors on metre scale optical surfaces induced by sub aperture figuring process, a new generation of non-contact plasma based surface figuring tools has been created at Cranfield University. In this context, this paper presents an investigation that focuses on novel enhanced nozzles that were created for a Radio Frequency (RF) Inductively Coupled Plasma (ICP) torch. The characteristics of plasma jet delivered by prototype nozzle and a selected enhanced nozzle are compared using an in-house created CFD model. The enhanced nozzle design is based on the results previously obtained throughout a numerical analysis that enabled to identify the key design aspects of these nozzles. This enhanced nozzle is predicted to provide 12.5% smaller footprint and 15.5% higher temperature.Item Open Access Characterisation and measurement to the sub-micron scale of a reference wire position(EDP Sciences, 2015-09-21) Sanz, Claude; Cherif, Ahmed; Mainaud-Durand, Hélène; Morantz, Paul; Shore, PaulItem Open Access Characterisation of wear resistance of natural and synthetic diamond tools during single point diamond turning(Cranfield University, 2013-02) Kirkwood, Leigh; Shore, Paul; Durazo-Cardenas, IsidroAchievable cutting distance of a diamond tool during turning is finite and is a limiting factor in the size of component that can be turned. This limit is particularly problematic when attempting to turn brittle materials, such as those used in infra-red optics. Natural diamond tools have been used for this application. However natural diamond introduces problems: the gems can contain possible contamination with a range of impurities and strong residual stresses from formation. Cutting distance is therefore inconsistent when using natural diamond. Industry is keen to increase possible cutting distance and to increase the consistency of cutting distance. One possible solution is synthetic diamond materials. New CVD single crystal synthetic diamonds possess high purity and consistent growth conditions and therefore have the potential to be a superior tool-material that provides longer achievable cutting distance and extremely consistent cutting behaviour. This new material is compared against natural and HPHT synthetic diamonds in machining tests against silicon workpieces in a selection of tool-orientations. Aluminium workpieces are machined with MCC and natural diamond tools to assess the performance of the new material against this commonly diamond turned material. While analysing the results from these cutting trials the failure modes of diamond tools were examined closely, resulting in discovering the existence of two separate failure modes and the development of a new wear-model. Natural diamond tools were carefully tested using a range of techniques hoping to find a root cause of the wide variability seen. FTIR offered a strong clue as to the defect within natural diamond tools that leads to occasional high cutting life.Item Open Access Design of and development a diamond fly-cutting system(2005) Jarrett, James; Shore, PaulThis thesis presents a conceptual design, for a single point diamond fly-cutting system. This design is based on the performance of an existing, diamond facing lathe. The design requirements for a precision machine tool have been considered, and a deterministic design philosophy has been adopted. The error motions within the diamond facing lathe are considered as effects, generated by defined causes. These causes include geometric, kinematic and dynamic sources. Diamond turning and flycutting processes have been compared and consideration has been given to the process influences, including variations in; diamond tool geometries, cutting forces, rotational error motions and the process characteristics required for an optimal surface finish. A single point diamond facing lathe has been refurbished and the dynamic error motions of this machine tool have been analysed, using different techniques. The stiffness properties have also been investigated, which indicate how the performance of the machine tool has been affected over time and during the refurbishment process. The dynamic error motions have been used to generate a set of technical specifications, governing the design of the fly-cutting system. A design concept has been presented and optimised. This includes a fly-cutting head, with a quick release tool holder based on a kinematically located side locking clamp. A design concept for a dynamic workpiece holder has also been presented, which monitors the error motions of the machine tool and orientates the workpiece accordingly. A three pair flexure system has been simulated to orientate the workpiece. Consideration has been given to mounting the workpiece, feedback transducers and the design of the control system. This thesis has provided the initial steps in the design of a single point diamond flycutting system. A further stage of development work is required to complete a detailed design.Item Open Access Dynamic Analysis of Aerostatic Guideway and FEA Model Development(Cranfield University, 2009-12) Lim, Chee Wang; Shore, Paul; Morantz, PaulA dynamically optimal design is essential for a motion system to perform high speed operation without compromising its accuracy, settling time and vibration specification. Good design practice which accounts for dynamic characteristics in the modelling of a motion system warrants higher performance precision machines and cuts down redevelopment effort to ‘patch’ inherent shortcoming of the machine dynamics. This research aimed to accurately describe the non-linear dynamics of a non-mechanical contact aerostatic guideway system in order to achieve an accurate FEA model of the design stage. The single axis aerostatic guideway is comprised of several machine in¬terfaces that impact the dynamic behaviour of the guideway. Modelling each air bear¬ing pad by a single stiffness element is not adequate to predict the guideway modal behaviour accurately. The aerostatic guideway has been broken down into several key machine interface elements. In-depth investigation of the air film and the air bearing mounting mechanism was carried out. A dedicated air film test rig was designed and built to acquire insight of the air film dynamic characteristics. It is observed that the mounting mechanism of the air bearing constitutes to a signifi-cant dynamic effect to the entire air bearing setup. Based on the findings of the mount-ing mechanism’s stiffness properties, a method was developed to estimate ‘true’ air gap heights which cannot be easily assessed and measured directly in most aerostatic guideway carriages. The estimation method enables a more rigorous FE model of the aerostatic guideway system. The comprehensive dynamic analysis methodology pro-posed in this research greatly increases the confidence and accuracy of the aerostatic guideway’s FE model.Item Open Access Electrolytic in-process dressing superfinishing of spherical bearings using metal-resin bond ultra-fine CBN wheels(Professional Engineering Publishing, 2011-01-01T00:00:00Z) Raffles, Mark H.; Stephenson, David J.; Shore, Paul; Jin, T.The use of electrolytic in-process dressing (ELID) superfinishing has been investigated with the aim of substantially improving surface finish on spherical bearing balls as well as reducing process times. Using ELID in a superfinishing configuration is substantially different from the more conventional precision grinding set-up. With this ELID superfinishing system, metal-resin bonded (MRB) wheels containing very small superabrasives (30 to 0.12 μm) were employed. Surface finishes of 2 nm Ra were achieved with a #12 000 wheel, an order of magnitude better than balls produced using the conventional production techniques of barrelling or polishing. Consistently sub-10 nm Ra finishes were achieved with a #2000 wheel. Different ways of using the ELID system, including ELID 1, ELID 2, and ELID 3, were studied to examine how the different types control the cutting condition at the wheel's surface. It is the ability to control easily the cutting condition of superabrasives of this size that allows mirror surface finishes to be efficiently produced. Monitoring of wheel spindle and ELID power usage was found to provide useful information in assessing the wheel cItem Open Access Elid superfinishing of spherical bearings(Cranfield University, 2007) Raffles, Mark H.; Stephenson, David J.; Shore, PaulDriven by a requirement to extend the lifespan of self-aligning lined spherical bearings, this research investigates the use of Elid (electrolytic in-process dressing) as a method of improving ball surface finish. Elid is a continuous and self-regulating electrochemical dressing process that modifies the surface of a grinding, lapping, or superfinishing wheel. It provides improved grit protrusion, impedes wheel loading / glazing and promotes effective cutting. The characteristics of the newly-developed Elid superfinishing process are in many ways fundamentally different to conventional superfinishing. The main difference is that the use of super-abrasives prevents the wheel from self-sharpening; the normal mechanism by which dulled conventional abrasives are removed and a wheel’s surface refreshed. Because the wheel’s performance and condition is continually maintained inprocess by the Elid system, metal resin bonded (MRB) wheels containing very small super-abrasives can be used. It is the utilization of these fine abrasives (30 to 0.12 μm) that enables surface roughness values below 5 nm Ra to be consistently produced on the spherical surface of corrosion-resistant steel balls. This research provides an in-depth understanding of the Elid spherical superfinishing process; investigating the most effective use of the Elid system, wheel dressing requirements and process performance. Optimisation is provided in terms of evaluating the critical operating parameters, the most effective superfinishing cycle and the implications to the complete ball production chain. A range of techniques are used to evaluate processing performance and ball output quality. These include in-process monitoring of Elid and wheel spindle power levels, analysis of wheel condition, rates of ball surface generation and material removal, ball finish and form. Although predominantly concentrated on corrosion-resistant steel, testing is also conducted on titanium and various ball coatings. In investigating various ways of using the Elid system, this work considers electrodischarge truing, pre-process dressing, Elid 1, Elid 2, Elid 3, and Elid combined with electrolytically assisted superfinishing. The initial process solution of Elid 3 (electrodeless) superfinishing provides the capability of working on all standard size balls, however the dressing system lacks stability. The development of a fixturing system that has a small separate electrode enables Elid 1 (conventional) to be used on the majority of ball sizes. Elid 1 allows more aggressive and consistent dressing, a faster rate of ball material removal and thus a substantially reduced processing time. Results with a #12,000 wheel show that surface quality is vastly improved through the use of Elid whilst maintaining current production standards of form accuracy. Surface finishes of 2nm Ra are achieved, which is an order of magnitude better than balls currently produced using barrelling / polishing. Processing times are equivalent or faster when using Elid 1. Alternatively, consistently sub 10 nm Ra finishes can be reached with a #2,000 wheel using Elid 2 (interval dressing). Generally MRB-CBN wheels provide a more effective carbide cutting action than conventional superfinishing wheels. Controlling wheel condition and achieving full and even ball to wheel conformity are the two most significant contributory factors to the success of Elid spherical superfinishing. Insufficient control of these factors results in poor output quality. Monitoring of wheel spindle and Elid power usage provides useful information in assessing the condition of the wheel and identifying potential problems. High spindle power correlates with fast material removal and is a result of high loads and a free cutting action. Elid processing can be employed for improving surface finish after the conventional honing stage, or after cylindrical grinding for improving both ball form and finish.Item Open Access Estimation of the power absorbed by the surface of optical components processed by an inductively coupled plasma torch(Elsevier, 2016-08-06) Jourdain, Renaud; Castelli, Marco; Yu, Nan; Gourma, Mustapha; Shore, PaulThe focus of this work is the determination of the heat flux function -thermal footprint- of a plasma jet generated by an inductively coupled plasma (ICP) torch. The parameters of the heat flux function were determined through the correlation of modelling and experimental results. One surface of substrates was exposed to an impinging jet while the temperature changes of the unexposed surface was recorded, analysed and used to derive the parameters of the heat flux function. From a modelling viewpoint, a series of finite element analyses (FEA) were carried out to predict temperatures of substrate surfaces. From an experimental viewpoint, the plasma torch was powered by a 1 kW radio frequency signal generator tuned at 39 MHz. The ICP torch equipped with a De-Laval nozzle impinged the surfaces of selected substrates at atmospheric pressure. Three sets of experiments -static, single pass and multi passes- were carried out to determine and validate the numerical description of the plasma jet. Also this work enabled to determine the maximum intensity of the heat flux distribution and the total power absorbed by substrate surfaces. Finally, the most advanced numerical model was used to assess the effect of a bi-directional raster scanning strategy that was used for the processing of large optical components.Item Open Access Evaluation of the performance variation of porous air pads on discontinuous surfaces(Elsevier, 2019-10-31) Sanz, Claude; Morantz, Paul; Lunt, Alexander J. G.; Shore, Paul; Chérif, Ahmed; Schneider, Jürgen; Mainaud-Durand, Hélène; Steffens, NorbertA new high accuracy position measurement system has been developed. It measures the position of a 0.1 mm diameter copper-beryllium wire that informs alignment of energy beams in advanced particle accelerators. This new measurement system employs air pads to provide precision and friction free rotation of a sensor. To enable the measuring system to be positioned over the wire, a slot is required in the measuring device rotor. To optimise the design of this measuring system it was necessary to understand the performance of the air pads as they pass over the gaps (slots) in the rotor. This paper describes modelling and experiments that were performed to gain understanding of air pad performance when encountering such a surface gap. Particularly, an analytical model of the variation of load of a 20 mm × 40 mm porous air pad during the passing of a 1.5 mm wide slotted surface. Subsequent experimentation revealed that the general behaviour of the load variation had been captured effectively. The results of this analysis reveal that air pads of this size can reliably pass above an opening of this size with about 14% reduction in force. The results and the methodology presented in this paper can be used as an effective basis for future designs and studiesItem Open Access Fast figuring of large optics by reactive atom plasma(2012-09-13T00:00:00Z) Castelli, Marco; Jourdain, Renaud; Morantz, Paul; Shore, Paul; Ramón, Navarro; Colin, R. Cunningham and Eric Prieto.The next generation of ground-based astronomical observatories will require fabrication and maintenance of extremely large segmented mirrors tens of meters in diameter. At present, the large production of segments required by projects like E-ELT and TMT poses time frames and costs feasibility questions. This is principally due to a bottleneck stage in the optical fabrication chain: the final figuring step. State-of-the-art figure correction techniques, so far, have failed to meet the needs of the astronomical community for mass production of large, ultra-precise optical surfaces. In this context, Reactive Atom Plasma (RAP) is proposed as a candidate figuring process that combines nanometer level accuracy with high material removal rates. RAP is a form of plasma enhanced chemical etching at atmospheric pressure based on Inductively Coupled Plasma technology. The rapid figuring capability of the RAP process has already been proven on medium sized optical surfaces made of silicon based materials. In this paper, the figure correction of a 3 meters radius of curvature, 400 mm diameter spherical ULE mirror is presented. This work demonstrates the large scale figuring capability of the Reactive Atom Plasma process. The figuring is carried out by applying an in-house developed procedure that promotes rapid convergence. A 2.3 μm p-v initial figure error is removed within three iterations, for a total processing time of 2.5 hours. The same surface is then re-polished and the residual error corrected again down to& lambda;/20 nm rms. These results highlight the possibility of figuring a metre-class mirror in about ten hours.Item Open Access Grinding metre scale mirror segments for the E-ELT ground based telescope(Technische Rundschau, Hallwag Publishers; 1999, 2011-04-21T00:00:00Z) Comley, Paul; Morantz, Paul; Shore, Paul; Tonnellier, XavierThe next generation of ground based telescopes require many hundreds of metre scale off-axis mirrors. In this paper the grinding of a 1.45m scale Zerodur® mirror segment for the European Extremely Large Telescope (E-ELT) is introduced. Employing an R-theta grinding mode with a multi stage grinding process material removal rates of up to 187.5mm3/s are achieved, whilst typically removing up to 1mm depth of material in total. Results show a RMS form error of <1μm, with subsurface damage <10μm, and a production cycle time under 2
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