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1、<p><b>  英文原文</b></p><p>  Development of the 3D-Designed Lathe Fixture of a Float Brake Caliper</p><p>  PAN Jin-kun1, ZUO Wan-li2, LU Dong-sheng2</p><p>  1School

2、 of Mechanical Engineering, Nanjing Institute of Technology, Nanjing 211167, P. R. China</p><p>  2College of Mechanical& Power Engineering, Nanjing University of Technology, Nanjing 210009, P. R. China&

3、lt;/p><p>  Abstract:According to the technique requests of the brake caliper in the process of production, a special fixture of float brake caliper has been developed based on 3D design in this paper. The deve

4、lopment process and verified data from 3D modeling and kinematics simulation for this special fixture show that this 3D-designed process can conveniently forecast the assembly interference of the fixture and accurately a

5、dd the mass of lead brick before the prototype is made. In this way the flutter ca</p><p>  Key words: 3D design; brake calipers; lathe fixture</p><p>  1 Introduction</p><p>  In t

6、he production of the float disc brake caliper of an automobile, due to the complexity of its structure, a special fixture is needed for installing and clamping the brake caliper. According to the technique requests of th

7、e brake caliper in the processing, a special fixture of float brake caliper is developed based on 3D design in this paper and its 3D model is assembled virtually. Through the mechanism simulation function of 3D design so

8、ftware, the balance of a lathe fixture is analyzed [1]. </p><p>  2 3D design of the special lathe fixture</p><p>  The manufacture object of the special fixture is the brake caliper of a float

9、disc brake, shown as Figure 1; its machining surface is the cylinder hole of the brake. The figure shows: when the cylinder hole is being processed, its axis and the machine spindle rotation axis must be in coincidence.

10、Due to irregular shape structure of the brake caliper, the flutter which is caused by the unbalance mass posed by the fixture and the work piece would affect the machining accuracy and roundness of the </p><p&

11、gt;  According to the shape structural characteristics of the brake caliper and the clamping requirements of the lathe fixture, the cylinder hole should be completed after a clamping of the lathe fixture in the whole pro

12、cessing. The flange needs the mounting hole of machine tool spindle and location hole of the fixture on both sides of the center as a middle ware connecting the machine tool spindle and the fixture. It is ensured that th

13、e axis of the processing cylinder hole of the caliper body which </p><p>  The modeling process of other parts of the special fixture is not depicted in detail in this paper,please refer to Reference[4] . Th

14、en these parts are assembled into two components, up and down, as shown in Figure 3 and Figure 4. The whole fixture is divided into two components when it is being assembled. This can avoid the parts being missed or inst

15、alled wrongly in the assembly process. In the component down, as the benchmark of flange, the counter balance is fixed with bolts. The counter balan</p><p>  In the component up, as the benchmark of the fixt

16、ure, the locating plate is fixed with seven bolts. Then as the benchmark of the locating plate, the upper half part of two threaded studs are rotated into the locating plate, and the pressure plate is clamped on the thre

17、aded studs by bolts. In the fixture, the pressure plate is in direct contact with the work piece, so it is under great stress. Therefore, the material of 45Mn2 is selected, which needs treatment of quenching and temperin

18、g. Matching</p><p>  Figure 1 Brake calipers Figure 2 Flange</p><p>  Figure 3 Component down Figure 4 Component up</p><p>  After the assemb

19、lies of component up and component down are completed, they are combined in a new component unit, with the bolts and nuts, as shown in Figure 5 shows. Due to adopting hierarchical assembly [5] , it is rational in the pra

20、ctical production process and the parts management is easy, which can effectively shorten the design cycle.</p><p>  Figure 5 Component unit1</p><p>  3 Balance analysis of the kinematics of the

21、 special lathe fixture</p><p>  The mass of each part needs to be determined before the process of kinematics simulation of the special lathe fixture. As is shown in Figure 6, the material and density of eac

22、h part is defined by menu command [mechanism] / [quality attributes], as Table 1 shows, the volume and mass of part are calculated out by 3D design software. We select carbon steel as the material of other standard parts

23、 such as the bolts and nuts, its density is 7.85g / cm3. In the process of defining the mass on Pro /E, u</p><p>  Figure 6 Dissection figure of the fixture</p><p>  Table 1 Material and density

24、 of the main parts of fixture</p><p>  Establishing component unite, and then, component unit1 would be assembled on the main shaft as the benchmark of machine spindle axis by the way of “connection-pin conn

25、ection”, as is shown in Figure7. After entering a mechanic model, the gravity is set in a default value. In the column of “direction”, we set X: -1, other: 0. Added in a motor, its rotation rate is 360 r/min. Then a “run

26、” is established with its settings, “dynamic type” and “opening gravity” in the column of “external load”. Till </p><p>  The detailed locations of centroids in three directions of X, Y, Z can be obtained th

27、rough the measuring function of Pro /E. Because of setting the machine spindle axis of rotation as the Z axis, the distance of the centroid relative to the centre rotation can be determined only in need of the maximum of

28、 the centroid at the direction of X or Y. The measurement results of fixture simulated motion without a matching block is shown in Figure 8. When the fixture turned about 90°, the maximum deviati</p><p>

29、;  Figure 7 Component unite Figure 8 Position curve of centroid without matching block</p><p>  In order to meet the balance requirement a matching block need to be added to adjust the centroid, as sho

30、wn in Figure 4. After adding the matching block, return to analyze and then re-measure. The result is that the centroid is still not on the axis, but the distance of the centroid relative to the axis is shortened. In the

31、 case of increasing the thickness of the matching block, the modification and measurement is executed again and again in the simulation process. Through a number of tests, an </p><p>  According to the simul

32、ation result with a matching block, a lead brick whose thickness is 30 mm, volume is 3.72 105mm3, mass is 4.23 kg is casted in the specified groove of fixture to meet the balance requirements.</p><p>  The c

33、omparison of measured data of run-out tolerance between the new design and the old design is shown in Table 2.</p><p>  Figure 9 Position curve of centroid with matching block</p><p>  Table 2 M

34、easured data of run-out tolerance</p><p>  4 Conclusions</p><p>  According to the technological requirements of the cylinder of brake caliper in the processing, Pro /E is adopted in the develop

35、ment of 3D design, and the kinematics simulation research is done on the fixture combined with its mechanical simulation functions. The development process and verified data from 3D modeling and kinematics simulation for

36、 this special fixture show that 3D-designed process can conveniently forecast the assembly interference of the fixture and accurately add the mass of le</p><p>  References</p><p>  [1] Zhu L Y,

37、 Li B, Pro /ENGINEER motion simulation and finite element analysis. Beijing: Posts& Telecom Press, 2004( In Chinese)</p><p>  [2] Ding JH, Wu G Q, Application of Pro /E software in product development. M

38、achine Building& Automation, (7) : 17 ~ 18, 22, 2006 ( In Chinese)</p><p>  [3] Anon, Adhesives and automobiles. Assembly Headquarters, ( 1) : 52~ 59, 2008</p><p>  [4] Wan Z J, Luo X G, Aut

39、omobile Oil-Pipe-Check-Tool Design Based on Pro /E Model. Automobile Technology & Material, ( 7) : 17 ~18, 22, 2006( In Chinese)</p><p>  [5] Qin G H, Zhang W H. Advanced design methods for machine tool

40、fixture. Beijing: Aviation Industry Press, 2006( In Chinese)</p><p>  Brief Biographies</p><p>  PAN Jin-kun is a lecturer in the School of Mechanical Engineering, Nanjing Institute of Technolog

41、y. His research interest is in mechanical design and theory. </p><p>  ZUO Wan-li is a postgraduate student in College of Mechanical and Power Engineering of Nanjing University of Technology. His research in

42、terest is in mechanical design and theory.</p><p>  LU Dong-sheng is a postgraduate student in College of Mechanical and Power Engineering of Nanjing University of Technology. His research interest is in mec

43、hanical design and theory.</p><p><b>  中文譯文</b></p><p>  基于三維設(shè)計(jì)的浮動(dòng)式制動(dòng)卡鉗的車床夾具的研制[1]</p><p>  潘金坤1,左萬里2,路東升2</p><p>  1南京工程學(xué)院機(jī)械工程學(xué)院,南京 211167,中華人民共和國</p>

44、;<p>  2南京工業(yè)大學(xué)機(jī)械與動(dòng)力工程學(xué)院,南京210009,中華人民共和國</p><p>  摘要:根據(jù)制動(dòng)卡鉗在生產(chǎn)過程中的技術(shù)要求,本文研究的是一個(gè)基于三維設(shè)計(jì)的浮動(dòng)式制動(dòng)卡鉗的專用夾具。根據(jù)專用夾具的三維建模和運(yùn)動(dòng)仿真的開發(fā)過程和驗(yàn)證數(shù)據(jù)顯示,三維設(shè)計(jì)過程可以在原型建模之前方便的預(yù)測夾具的組裝干涉和準(zhǔn)確添加在鉛磚的質(zhì)量。通過這種方式,可以消除由擺動(dòng)引起的車床夾具的不平衡和改善在缸孔與機(jī)

45、床主軸的跳動(dòng)公差精度,因此制動(dòng)卡鉗的缸孔加工質(zhì)量可以很大程度的被保證。</p><p>  關(guān)鍵字:三維設(shè)計(jì);制動(dòng)卡鉗;車床夾具</p><p><b>  1 緒言</b></p><p>  汽車的浮動(dòng)盤式制動(dòng)器卡鉗的生產(chǎn),由于其結(jié)構(gòu)的復(fù)雜性,需要專用夾具來安裝和夾緊制動(dòng)卡鉗。制動(dòng)器是汽車涉及行駛安全性的關(guān)鍵部件,隨著汽車工業(yè)的發(fā)展,車速越

46、來越高,載荷越來越大,而對(duì)制動(dòng)器的尺寸要求越來越小。這意味著制動(dòng)器部件單位面積所承受的載荷及吸收的能量會(huì)大大增加,因而對(duì)制動(dòng)器性能的要求也越來越高。對(duì)行駛的汽車進(jìn)行制動(dòng)時(shí),將摩擦部件(摩擦片)壓到車輛的轉(zhuǎn)動(dòng)部件(制動(dòng)盤)上,摩擦使轉(zhuǎn)動(dòng)部件減速或停止運(yùn)動(dòng),因此發(fā)熱是動(dòng)摩擦的必然結(jié)果。根據(jù)制動(dòng)卡鉗在加工中的技術(shù)要求,本文研究一個(gè)基于三維設(shè)計(jì)的浮動(dòng)制動(dòng)卡鉗的專用夾具和它的模型的虛擬裝配。通過三維設(shè)計(jì)軟件的機(jī)構(gòu)仿真功能,分析車床夾具的平衡性[1

47、]。結(jié)果顯示這個(gè)設(shè)計(jì)過程可以方便的預(yù)測一些影響技術(shù)設(shè)備質(zhì)量的因素,例如在樣機(jī)里的裝配干涉和車床夾具的加工穩(wěn)定性[2]。這個(gè)設(shè)計(jì)過程不僅可以避免在傳統(tǒng)設(shè)計(jì)里的設(shè)計(jì)誤差,還可以提高產(chǎn)品的設(shè)計(jì)質(zhì)量。</p><p>  2 專用車床夾具的三維設(shè)計(jì)</p><p>  專用夾具的制造對(duì)象是浮動(dòng)盤式制動(dòng)器的制動(dòng)卡鉗,如圖1所示;其加工表面是制動(dòng)器的缸孔。這個(gè)圖顯示:當(dāng)缸孔被加工時(shí),它的軸必須符合機(jī)器

48、主軸的旋轉(zhuǎn)軸。由于制動(dòng)卡鉗的不規(guī)則形狀結(jié)構(gòu),夾具的不平衡質(zhì)量引起的擺動(dòng)和工件會(huì)影響缸孔實(shí)際加工中的加工精度和圓度,和一些形狀公差的精度要求例如兩缸孔之間的平行度。為了避免制動(dòng)卡鉗的車床夾具在設(shè)計(jì)過程中的這些問題,在本文研究了專用夾具的三維設(shè)計(jì)。</p><p>  根據(jù)制動(dòng)卡鉗的形狀結(jié)構(gòu)特點(diǎn)和車床夾具的夾緊要求,在整個(gè)加工過程中,缸孔應(yīng)該在車床夾具夾緊后來完成。法蘭需要機(jī)器主軸的安裝孔和夾具兩邊的中心定位孔作為中

49、介來連接機(jī)器主軸和夾具。確??ㄣQ機(jī)體加工缸孔的軸的定位和在夾具的夾緊和機(jī)器旋轉(zhuǎn)主軸的相互配合[3],如圖2所示。</p><p>  在本文中,專用夾具的其他部分的建模過程不進(jìn)行詳細(xì)描述,請(qǐng)參考文獻(xiàn)[4]。然后這些零件組裝成兩個(gè)部分,上部分和下部分,如圖3和圖4所示。在裝配時(shí),整個(gè)夾具分兩個(gè)部分。這樣在裝配過程中避免零件被少裝或安裝錯(cuò)誤。在下部分,作為法蘭的基準(zhǔn)由螺栓來實(shí)現(xiàn)平衡的固定。在夾具生產(chǎn)過程中,柜臺(tái)平衡會(huì)

50、被平衡調(diào)節(jié)。在正常工作狀態(tài)下,根據(jù)浮鉗盤式制動(dòng)器工作原理,在靜力的某一平衡狀態(tài)下,制動(dòng)鉗受力如下:(1)制動(dòng)盤反作用力通過內(nèi)側(cè)摩擦, 活塞和制動(dòng)液介質(zhì)作用在制動(dòng)鉗體的油缸側(cè)壁。(2)制動(dòng)盤反作用力通過外側(cè)摩擦塊對(duì)鉗體產(chǎn)生一個(gè)推力。(3)與支架相接螺栓孔處有來自支架對(duì)鉗體的作用力。</p><p>  在上部分,作為夾具的基準(zhǔn),用七個(gè)螺栓來固定定位板。然后,作為基準(zhǔn)的定位板,上半部分由兩個(gè)螺紋釘定在定位板上,和壓

51、緊板通過螺栓被夾緊。在夾具里,壓緊板是直接接觸工件的,所以它收到巨大的壓力。因此,材料選擇45Mn2,需要淬火和回火的熱處理。在初始裝配中,配合塊不需要固定在夾具上,配合塊的質(zhì)量在運(yùn)動(dòng)仿真的結(jié)果中可以得到。</p><p>  在上部分和下部分裝配完成后,他們由螺栓和螺母組成了一個(gè)新的單元1,如圖5所示。由于采用層次化裝配[5],在實(shí)際生產(chǎn)過程中它是合理的,部分管理是簡單的,可以有效的縮短設(shè)計(jì)周期。</p&

52、gt;<p>  3 專用車床夾具的運(yùn)動(dòng)學(xué)平衡性分析</p><p>  每個(gè)零件的質(zhì)量需要在專用夾具的運(yùn)動(dòng)仿真過程特性之前確定。如圖6所示,每個(gè)零件的材料和密度是由菜單欄里的[機(jī)構(gòu)]/[質(zhì)量屬性]來確定的,如表1所示,零件的體積和質(zhì)量是由三維設(shè)計(jì)軟件計(jì)算的。我們選擇碳素鋼作為其他標(biāo)準(zhǔn)零件的材料,如螺栓和螺母,其密度是7.85g / cm3。在Pro/E里的定義質(zhì)量的過程,也要注意單位轉(zhuǎn)換。<

53、/p><p>  建立組件單元,然后,組件單元1將通過“連接銷連接”安裝在主軸上作為機(jī)器主軸的基準(zhǔn),如圖7所示。在進(jìn)入力學(xué)模型后,重力是一個(gè)設(shè)定的默認(rèn)值。在矢量列表中,我們?cè)O(shè)置X:-1,其他:0。添加一個(gè)電動(dòng)機(jī),它的轉(zhuǎn)速是360 r/min。然后建立在外部負(fù)載列表里的動(dòng)態(tài)式和打開重力的設(shè)置為運(yùn)行。直到那時(shí),運(yùn)動(dòng)學(xué)仿真過程才可以運(yùn)行。為了減少缸孔的擺動(dòng),專用夾具的平衡是本文的關(guān)鍵分析[6,7]。平衡性分析的目的是夾具和

54、工件在機(jī)床的旋轉(zhuǎn)主軸的整體重心。因此,我們首先要確定夾具和工件的整體質(zhì)心。然后整體和主軸之間的距離就可以得到。整體和主軸之間的距離應(yīng)該趨向于零,盡可能調(diào)整配合塊的質(zhì)量。</p><p>  質(zhì)心的具體三個(gè)方向因子的X,Y,Z可以通過Pro/E的測量功能得到。因?yàn)樵O(shè)置機(jī)床的旋轉(zhuǎn)主軸為Z軸,質(zhì)心相對(duì)于旋轉(zhuǎn)中心的距離只需要質(zhì)心在X或Y方向的最大值來確定。沒有配合塊的夾具虛擬運(yùn)動(dòng)的測量結(jié)果如圖8所示。當(dāng)夾具轉(zhuǎn)動(dòng)90

55、76;,質(zhì)心的最大偏差距離在X方向是-22.08mm。只有這樣做,我們可以知道質(zhì)心不在軸上;作為它不能滿足平衡要求的條件。</p><p>  表1 夾具主要零件材料與密度</p><p>  為了滿足平衡條件的配合塊需要添加調(diào)整質(zhì)心,如圖4所示。在添加配合塊后,回歸分析,然后重新測量。結(jié)果是質(zhì)心依然不在軸上,但質(zhì)心相對(duì)于軸的距離縮短了。對(duì)于配合塊的厚度增加,修改,測量是一次又一次的執(zhí)行仿

56、真過程。通過大量的測試,得到質(zhì)心相對(duì)于軸的理想距離。這個(gè)值是1.5 10-7mm,如圖9所示,因此它可以被認(rèn)為是質(zhì)心在軸上和滿足平衡需求的結(jié)果。</p><p>  根據(jù)配合塊的運(yùn)動(dòng)仿真結(jié)果,一個(gè)鉛磚的厚度是30mm,體積是3.72105mm3,質(zhì)量是4.23kg是滿足平衡性要求的專用槽夾具。在新的設(shè)計(jì)與舊的設(shè)計(jì)之間的跳動(dòng)公差的測量數(shù)據(jù)的比較如表2所示。</p><p>  表2 跳動(dòng)公差

57、測量數(shù)據(jù)</p><p>  制動(dòng)器在車輛安全性方面起著相當(dāng)重要的作用,直接影響到這些車輛的正常行駛,因而制動(dòng)器總成及其零部件的安全可靠性倍受關(guān)注。運(yùn)用CAD/CAE 技術(shù)對(duì)某浮鉗式盤式制動(dòng)器的關(guān)鍵零件進(jìn)行了有限元分析,分析結(jié)果表明制動(dòng)鉗體等關(guān)鍵零件滿足設(shè)計(jì)強(qiáng)度要求。當(dāng)制動(dòng)時(shí),活塞在液壓力的作用下推動(dòng)內(nèi)摩擦塊沿著導(dǎo)向銷軸向移動(dòng),以一定的壓力壓向制動(dòng)盤,同時(shí)制動(dòng)鉗鉗體也在液壓反向力作用下將外制動(dòng)盤以一定壓力壓向制動(dòng)

58、盤,這時(shí)摩擦襯片便于制動(dòng)盤間產(chǎn)生摩擦力,從而達(dá)到制動(dòng)的目的。在制動(dòng)過程中,當(dāng)受力的平衡狀態(tài)下,制動(dòng)鉗鉗體受力為:(1)制動(dòng)盤反作用力通過內(nèi)側(cè)摩擦塊,活塞和制動(dòng)液作用在鉗體的油缸側(cè)壁。(2)制動(dòng)盤反作用力通過外側(cè)摩擦塊對(duì)鉗體產(chǎn)生一個(gè)推力。(3)與支架相接螺栓孔處又來自支架對(duì)鉗體的作用力。制動(dòng)器支架的受力情況為:①制動(dòng)盤與摩擦襯塊間的摩擦力</p><p>  通過制動(dòng)底板傳到支架的一側(cè),來自與支架滑槽相觸的是制動(dòng)底

59、板對(duì)滑槽的壓力,而壓力的大小取決與摩擦片圓周摩擦力的大??;②支架固定處來自轉(zhuǎn)向節(jié)的反作用力;③與鉗體相接處來自鉗體的反作用力。通過對(duì)該浮鉗盤式制動(dòng)器的關(guān)鍵零件進(jìn)行受力分析,這些作用力將作為載荷邊界條件添加到有限元分析模型中。</p><p>  在UG4.0 軟件建立該型號(hào)浮鉗盤式制動(dòng)器三維模型后,通過軟件集成技術(shù)將模型導(dǎo)入到UG 集成的有限元前處理模塊“simulation design”中自動(dòng)劃分網(wǎng)格[4]。

60、網(wǎng)格劃分前,需要簡化模型,可以減少分析求解所需要的時(shí)間。為了能準(zhǔn)確地反應(yīng)各零件的應(yīng)力、應(yīng)變及位移的規(guī)律,采用10 節(jié)點(diǎn)四面體單元作為劃分網(wǎng)格類型。完成網(wǎng)格劃分后,可在屬性編輯器評(píng)價(jià)和修改網(wǎng)格屬性以改進(jìn)網(wǎng)格,這樣能在邊緣和高應(yīng)力處細(xì)化和改善網(wǎng)格。</p><p>  通過定義好網(wǎng)格和作用邊界條件準(zhǔn)備好有限元模型。就可以執(zhí)行解算。需注意的是,為確保成功解算和精確結(jié)果,有限元模型的檢查是必需的,解算前先創(chuàng)建分析方案,將

61、仿真文件導(dǎo)入Nastran 求解器解算,順利求解后在仿真導(dǎo)航器中可顯示計(jì)算結(jié)果,在后處理模塊中,顯示或編輯相關(guān)零件的位移,應(yīng)力或應(yīng)變等指標(biāo)。通過后處理模塊,我們能通過云圖直觀形象地得到位移,應(yīng)力應(yīng)變的變化和顯示,并可以以動(dòng)畫等方式顯示零件中最危險(xiǎn)的部位。我們能直接觀察和讀取活塞,制動(dòng)鉗支架和制動(dòng)鉗鉗體的應(yīng)力,并了解到各零部件是否滿足強(qiáng)度要求。</p><p><b>  4 結(jié)論</b>&l

62、t;/p><p>  根據(jù)制動(dòng)卡鉗的缸孔的技術(shù)要求在加工、Pro/E中結(jié)合夾具中的機(jī)械仿真功能采用三維設(shè)計(jì)的研究和運(yùn)動(dòng)學(xué)仿真的研究。根據(jù)專用夾具的三維建模和運(yùn)動(dòng)仿真的開發(fā)過程和驗(yàn)證數(shù)據(jù)顯示,三維設(shè)計(jì)過程可以在原型建模之前方便的預(yù)測夾具的組裝干涉和準(zhǔn)確添加在鉛磚的質(zhì)量。這樣我們可以消除由車床夾具的不平衡引起的擺動(dòng)和提高缸孔與機(jī)床主軸的跳動(dòng)公差精度,從而保證制動(dòng)卡鉗的缸孔的加工質(zhì)量。</p><p&g

63、t;<b>  參考文獻(xiàn)</b></p><p>  [1] 祝凌云,李斌.Pro/ENGINEER 運(yùn)功仿真和有限元分析.北京:人民郵電出版社,2004.</p><p>  [2] 丁錦宏,吳國慶.Pro/E軟件在新產(chǎn)品設(shè)計(jì)中的應(yīng)用.機(jī)械制造與自動(dòng)化,2008(8):138-139,152.</p><p>  [3] Anon, Adhe

64、sives and automobiles. Assembly Hesdquarters,2008(1):52-59.</p><p>  [4] 秦國華,張衛(wèi)紅.機(jī)床夾具的現(xiàn)代設(shè)計(jì)方法.北京:航空工業(yè)出版社:(2006).</p><p>  [5] 萬志堅(jiān),羅顯光.基于Pro/E建模的汽車油管檢具設(shè)計(jì).汽車工藝與材料,2006(7):17-18,22.</p><p

65、><b>  簡介</b></p><p>  潘金坤是南京工程學(xué)院機(jī)械工程學(xué)院的一個(gè)講師,他的研究興趣在機(jī)械設(shè)計(jì)及理論。</p><p>  左萬里是南京工業(yè)大學(xué)機(jī)械與動(dòng)力工程學(xué)院的研究生,他的研究興趣是機(jī)械設(shè)計(jì)及理論。</p><p>  路東升是南京工業(yè)大學(xué)機(jī)械與動(dòng)力工程學(xué)院的研究生,他的研究興趣是機(jī)械設(shè)計(jì)及理論。</p>

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