The automotive industry has greatly promoted the technological advancement and market expansion of diamond and CBN tools, and will continue to be the main application area for diamond and CBN tools. This article discusses the trends in the automotive industry, today's diamond and CBN tool technologies and their applications in modern production lines. This paper also provides an overview of the advanced processing techniques that are expected to be applied to future production processes, and predicts the future development of diamond and CBN tools that are essential to meeting the future of automotive technology.
Over the past eight years (1997-2004), global car production has increased by about 14%. Car production in North America, Europe and Japan has grown very little, while in Asia and elsewhere, growth has been significant. The largest auto producers currently include the United States, Japan, Germany and other Western European countries as well as China. The so-called “BRIC†countries (Brazil, Russia, India and China) are experiencing significant growth in vehicle production, and marketing strategies in these countries will be a key factor in growth strategies for the next few years.
Today, the basic strategy of automakers is to develop and apply advanced technologies that adapt to current automotive trends such as environmentally friendly, energy efficient vehicles, safety, information communications and globalization. Figure 2 shows the various trends in automotive technology and the processing needs stemming from new production requirements. In order to meet new production requirements, efficient, flexible and environmentally friendly manufacturing techniques are required. In general, these processing techniques are required to achieve high speed, high efficiency and high precision. Given the cost factors and market base, the current mainstream automotive powertrain (composed of engines and gearboxes) is expected to maintain its core technology position for the foreseeable future. Hybrid vehicles use the engine with an electric motor, but the application of the electric motor keeps the cost high. Technological advances that can reduce the high cost of hybrid vehicles will be a key factor in determining the penetration rate of such vehicles. Automobiles that are fully powered by electric motors (such as fuel cell vehicles) also face many problems, including the complexity of the automotive system, the lack of necessary market base, and high costs. At this stage, the launch of these vehicles will still be based primarily on experimental nature, with the aim of accumulating the required technology. In summary, the processing needs for these automotive products include the processing of new shapes, new materials and ultra-finishing, which have not been used in conventional engine and gearbox processing.
Technical status of diamond and CBN tools in the automotive industry
As we all know, the automotive industry is the most important market for tool manufacturers. From the changes in the annual output value of Japanese cars and tools in recent years (1997-2005), it can be seen that the change in the total output value of the tool has a good correlation with the change in the total output value of the automobile. In 2005, compared with 1997, the total output value of automobiles increased by about 13%, while the total output value of tools increased by about 13.6%. From the perspective of the types of tools, the growth rate of cemented carbide tools is the highest, followed by diamond and CBN tools. In contrast, the output value of special tools and grinding wheels has declined. The narrower application range of diamond and CBN tools may be one of the reasons for the lower growth rate compared to cemented carbide tools. This also shows that expanding the range of applications for diamond and CBN tools is a key factor in expanding their demand.
During the same period (1997-2005), from the changes in the annual output value of diamond and CBN tools in Japan, the total output value of diamond and CBN tools increased only slightly in 2005 compared with 1997. Among them, CBN tools have the largest growth rate of output value, about 70%; diamond tools second; followed by diamond grinding wheels. These types of tools are directly related to automobile manufacturing. Considering this data together with the previous data, it can be seen that although the application range of diamond and CBN tools is narrow, it is expanding. We can also see that the output value of segmented tools, cutting tools and other tools is dropping sharply, which may reflect the decreasing demand in the field of construction and public works, which were previously the main users of diamond tools. It can be expected that, at least in Japan, the market for diamonds and CBN tools in the automotive industry and industrial machinery industry (represented by electromechanical and similar products) will continue to expand in the coming years.
A summary of the processing requirements for automotive parts shows the processing methods required to meet product and production requirements. Tool requirements associated with these processing methods include such properties as high hardness, heat resistance, long tool life, sharpness of the cutting edge, and good thermal conductivity. Diamond and CBN tools are just right to provide these high levels of processing performance.
Production systems have evolved from machine tool lines in the 1970s to flexible processing lines capable of producing different varieties and different quantities of products in the 2010s. In this development of production systems, some of the epoch-making technological advances are related to tools and grinding. Without the diamond and CBN tools, these processing techniques will not be possible. In other words, many new processing technologies have been developed and implemented over the years along with advances in diamond and CBN tools.
Application of diamond and CBN tools on the production line
The main use of diamond and CBN tools in the machining of automotive powertrain components: Diamond tools are used to machine aluminum alloy parts (such as cylinder heads and cylinder blocks). The main applications are boring and surface finishing (such as end face machining). Drilling and roughing are mainly done with carbide tools. CBN tools are used to machine cast iron and steel parts such as crankshafts and camshafts. Diamond tools are used for machining operations where the cutting speed is relatively slow (such as honing and surface finishing). In recent years, the application of hard turning has also increased. It is important to point out that diamond and CBN tools are used in processing applications where it is difficult to achieve higher processing efficiencies, such as machining hardened materials and for high speed machining. In general, diamond and CBN tools increase cutting speed by a factor of 2 to 10 compared to conventional carbide tools or white fused alumina wheels. Since the machining efficiency is proportional to the cutting speed, significant economic benefits can be obtained with diamond and CBN tools where the workpiece material can be machined at the highest possible cutting speed.
Typical applications for diamond and CBN tools on the production line are described below. For example, diamond and CBN tools are used to machine cylinder blocks and cylinder heads. In addition to traditional surface finishing and boring, diamond and CBN tools have recently been used for drilling and reaming. Diamond and CBN tools that can withstand harsher processing conditions than conventional processing conditions are constantly being developed.
The application examples of high-precision cutting of aluminum alloy workpieces with single crystal diamond blades show that the single crystal diamond blades have sharper cutting edges and higher hardness than polycrystalline diamond (PCD) inserts, which can improve the final surface roughness obtained. Degree and can extend tool life. Although the cost of a single crystal diamond blade is about three times that of a PCD blade, it can still achieve very good economic benefits by giving full play to the performance advantages of a single crystal diamond tool.
When cylinder hole finishing is performed with CBN inserts and diamond honing blocks, the fine grinding and honing of the cylinder bores are integrated on one machine to improve machining accuracy and machining efficiency. The boring process uses a PCBN tool, and the honing process uses a single crystal diamond honing block. Both processes use a water soluble coolant.
When the ceramic bond CBN grinding wheel is used for high-speed grinding, the grinding speed currently used is 50-200 m/sec. High-speed grinding plays an important role in the flexible machining of the crankshaft, including the combined grinding of the pin and journal, due to the higher grinding speed and higher machining efficiency. Although high speed grinding is an effective way to increase processing efficiency, the process is still not widely used. The biggest problem facing high speed grinding is the establishment of process technologies that achieve satisfactory levels of reliability and cost.
At different wheel speeds, the relationship between grinding efficiency and tangential grinding force is that the tangential grinding force increases as the level of grinding efficiency increases, and the rate of increase depends on the wheel speed. The normal grinding force also shows the same trend. In other words, when the grinding wheel speed is high, the rate of increase of the grinding force is small. We apply this feature to the production line and perform ultra-high speed cam grinding at a grinding speed of 200 m/s. If the performance of the grinding wheel for high-speed grinding can be improved, it is possible to further expand its application range.
Latest research topics in diamond and CBN tooling technology
The test results obtained by high-efficiency precision turning of aluminum alloy by single crystal diamond (SCD) scraping blade show that the surface roughness is a function of the tool radius and the feed rate. When the radius of the tool nose is greater than 10 mm, a surface roughness of less than Ra of 0.1 μm can be obtained; at a high feed rate of 0.4 mm/rev, a tool having a radius of a large tool nose can be used to obtain a surface of Ra 0.1 μm. Roughness. These test results show that the process can increase the surface roughness by an order of magnitude while achieving the same high processing efficiency as conventional processing methods.
Test results obtained by precision hard turning with CBN inserts show that surface roughness is a function of feed rate. In this test, the surface roughness of Ra 0.03 μm was obtained by grinding the cutting edge of the cutter. An application example of machining a toroidal continuously variable transmission (CVT) disc with this technique shows that hard turning can replace conventional grinding and then final finishing of the disc with superfinishing.
The test results obtained by intermittently cutting hardened steel with CBN tools in the machining of the teeth indicate that the tool with the inclined cutting edge feeds in the tangential direction toward the workpiece during the machining of the teeth. In conventional machining with a cutting speed of 300 m/min, the tool breaks shortly after the start of the cutting process. In contrast, in the machining of the teeth using the CBN tool, the tool life calculated by the cutting length reached about 15 km. This result indicates that the tooth process can achieve efficient interrupted cutting of hardened steel.
Some of the research results on ultra-high speed grinding are described below. The relationship between the grinding efficiency and the surface roughness of some typical grinding methods indicates that the grinding efficiency tends to decrease as the surface roughness decreases with conventional grinding processes. Therefore, we have adopted a grinding wheel truncation to improve the surface roughness. In addition, we have invented a new concept of high-speed grinding and ultra-high-speed grinding as a way to further improve grinding efficiency. In this way, we strive to achieve a mirror-like surface grinding effect while achieving a higher level of grinding efficiency that was previously difficult to obtain.
The first application example is the use of a ceramic bond CBN grinding wheel for ultra-high speed grinding with ultra-high grinding wheels and workpiece speeds. In peripheral grinding with a grinding wheel speed of 240 m/s, the machined surface roughness is used as a function of the feed rate. Comparing the surface roughness values ​​at the general workpiece speed (40 m/min) and the high workpiece speed (520 m/min), the results show that even at a high workpiece speed of 520 m/min, the feed rate (ie, machining efficiency) is increased by 4 Above the surface, the surface roughness did not change substantially, and no white etching layer was observed on the cross-sectional micrograph. In other words, these results show that efficient machining can be achieved by simultaneously increasing the speed of the grinding wheel and the speed of the workpiece.
A second application example is the efficient grinding of mirror-like surfaces using ceramic bond CBN grinding wheels. The ratio of the machined surface roughness as a ratio of the dressing speed. When a large dressing lead of 0.1 mm/rev is used, the surface roughness value increases as the ratio of the dressing speed increases. On the contrary, when the small trimming lead of 0.01 mm/rev was used, the surface roughness was not significantly deteriorated. The photomicrograph shows the work-affected layer when the dressing lead is set to 0.01 mm/rev and the dressing speed ratio is 0.2 and 0.8, respectively. When the ratio of the dressing speed is 0.2, the white etching layer and the tempering layer can be observed; and when the ratio of the trimming speed is 0.8, these metamorphic layers are very small and hardly recognized. By applying this grinding technology, it is expected that mirror-like surface grinding of crankshafts and other parts can be achieved, and the same processing efficiency as conventional grinding methods can be obtained.
Future prospects for diamond and CBN tools
The two main foundations of the development strategy related to the automotive industry and processing technology are globalization and the development of new products and technologies. These two foundations will continue to evolve with the advancement of parent technologies such as machine tool technology, tool technology and other technologies. In order to remain competitive in the near future, companies will need to adapt to the evolving global processing technology. In order to achieve future growth, companies must develop processing technologies for the production of new products and have the resources to implement these technologies on a global scale. In order to expand the market for diamond and CBN tools, there is a need for development strategies that are associated with this technological advancement.
One question is: How big is the expansion space in the global market? Forecasts for global car ownership in the next few years estimate that car ownership in 2020 will be about 1.3 times higher than current levels. In Europe, North America, Japan and other mature automotive markets, car penetration has exceeded one car per two people. At present, the global car penetration rate is about one car per ten people. This data shows that the global automotive market will continue to grow in the coming years. In other words, a development strategy for diamond and CBN tooling technology needs to be developed to address this global growth in automotive demand.
In predicting the future of diamond and CBN tools, let's shift the perspective of considering the problem from quantitative growth to application expansion. Predictions of diamond and CBN tools related to changes in the materials of major components of automotive power systems indicate that aluminum, manganese and other light alloys, as well as titanium alloys, sintered alloys and other high-strength alloys, will increasingly be used as power system zeros in the future. The material of the part. Therefore, diamond tools capable of processing these materials are expected to have a very large increase.
Forecasts for future automotive technology developments indicate that automotive technology will evolve from current gasoline and diesel engines to motor-assisted, hybrid, and then further developed into fuel cell stacks. It will therefore be necessary to develop new diamond and CBN tooling technologies associated with this change.
According to forecasts, the short-term growth and medium- and long-term growth of automakers will continue to be optimistic. The author believes that it can be expected that diamond and CBN tool processing technology will be further developed by keeping up with the development trend of automotive technology and expanding the scope of processing applications. The author describes some trends in the automotive industry and introduces relevant diamond and CBN tool processing techniques from the perspective of automakers. It is hoped that the automotive industry and the diamond and CBN tool industry will continue to work together and develop together in the future.
Author: Zhang Xian compilation
Over the past eight years (1997-2004), global car production has increased by about 14%. Car production in North America, Europe and Japan has grown very little, while in Asia and elsewhere, growth has been significant. The largest auto producers currently include the United States, Japan, Germany and other Western European countries as well as China. The so-called “BRIC†countries (Brazil, Russia, India and China) are experiencing significant growth in vehicle production, and marketing strategies in these countries will be a key factor in growth strategies for the next few years.
Today, the basic strategy of automakers is to develop and apply advanced technologies that adapt to current automotive trends such as environmentally friendly, energy efficient vehicles, safety, information communications and globalization. Figure 2 shows the various trends in automotive technology and the processing needs stemming from new production requirements. In order to meet new production requirements, efficient, flexible and environmentally friendly manufacturing techniques are required. In general, these processing techniques are required to achieve high speed, high efficiency and high precision. Given the cost factors and market base, the current mainstream automotive powertrain (composed of engines and gearboxes) is expected to maintain its core technology position for the foreseeable future. Hybrid vehicles use the engine with an electric motor, but the application of the electric motor keeps the cost high. Technological advances that can reduce the high cost of hybrid vehicles will be a key factor in determining the penetration rate of such vehicles. Automobiles that are fully powered by electric motors (such as fuel cell vehicles) also face many problems, including the complexity of the automotive system, the lack of necessary market base, and high costs. At this stage, the launch of these vehicles will still be based primarily on experimental nature, with the aim of accumulating the required technology. In summary, the processing needs for these automotive products include the processing of new shapes, new materials and ultra-finishing, which have not been used in conventional engine and gearbox processing.
Technical status of diamond and CBN tools in the automotive industry
As we all know, the automotive industry is the most important market for tool manufacturers. From the changes in the annual output value of Japanese cars and tools in recent years (1997-2005), it can be seen that the change in the total output value of the tool has a good correlation with the change in the total output value of the automobile. In 2005, compared with 1997, the total output value of automobiles increased by about 13%, while the total output value of tools increased by about 13.6%. From the perspective of the types of tools, the growth rate of cemented carbide tools is the highest, followed by diamond and CBN tools. In contrast, the output value of special tools and grinding wheels has declined. The narrower application range of diamond and CBN tools may be one of the reasons for the lower growth rate compared to cemented carbide tools. This also shows that expanding the range of applications for diamond and CBN tools is a key factor in expanding their demand.
During the same period (1997-2005), from the changes in the annual output value of diamond and CBN tools in Japan, the total output value of diamond and CBN tools increased only slightly in 2005 compared with 1997. Among them, CBN tools have the largest growth rate of output value, about 70%; diamond tools second; followed by diamond grinding wheels. These types of tools are directly related to automobile manufacturing. Considering this data together with the previous data, it can be seen that although the application range of diamond and CBN tools is narrow, it is expanding. We can also see that the output value of segmented tools, cutting tools and other tools is dropping sharply, which may reflect the decreasing demand in the field of construction and public works, which were previously the main users of diamond tools. It can be expected that, at least in Japan, the market for diamonds and CBN tools in the automotive industry and industrial machinery industry (represented by electromechanical and similar products) will continue to expand in the coming years.
A summary of the processing requirements for automotive parts shows the processing methods required to meet product and production requirements. Tool requirements associated with these processing methods include such properties as high hardness, heat resistance, long tool life, sharpness of the cutting edge, and good thermal conductivity. Diamond and CBN tools are just right to provide these high levels of processing performance.
Production systems have evolved from machine tool lines in the 1970s to flexible processing lines capable of producing different varieties and different quantities of products in the 2010s. In this development of production systems, some of the epoch-making technological advances are related to tools and grinding. Without the diamond and CBN tools, these processing techniques will not be possible. In other words, many new processing technologies have been developed and implemented over the years along with advances in diamond and CBN tools.
Application of diamond and CBN tools on the production line
The main use of diamond and CBN tools in the machining of automotive powertrain components: Diamond tools are used to machine aluminum alloy parts (such as cylinder heads and cylinder blocks). The main applications are boring and surface finishing (such as end face machining). Drilling and roughing are mainly done with carbide tools. CBN tools are used to machine cast iron and steel parts such as crankshafts and camshafts. Diamond tools are used for machining operations where the cutting speed is relatively slow (such as honing and surface finishing). In recent years, the application of hard turning has also increased. It is important to point out that diamond and CBN tools are used in processing applications where it is difficult to achieve higher processing efficiencies, such as machining hardened materials and for high speed machining. In general, diamond and CBN tools increase cutting speed by a factor of 2 to 10 compared to conventional carbide tools or white fused alumina wheels. Since the machining efficiency is proportional to the cutting speed, significant economic benefits can be obtained with diamond and CBN tools where the workpiece material can be machined at the highest possible cutting speed.
Typical applications for diamond and CBN tools on the production line are described below. For example, diamond and CBN tools are used to machine cylinder blocks and cylinder heads. In addition to traditional surface finishing and boring, diamond and CBN tools have recently been used for drilling and reaming. Diamond and CBN tools that can withstand harsher processing conditions than conventional processing conditions are constantly being developed.
The application examples of high-precision cutting of aluminum alloy workpieces with single crystal diamond blades show that the single crystal diamond blades have sharper cutting edges and higher hardness than polycrystalline diamond (PCD) inserts, which can improve the final surface roughness obtained. Degree and can extend tool life. Although the cost of a single crystal diamond blade is about three times that of a PCD blade, it can still achieve very good economic benefits by giving full play to the performance advantages of a single crystal diamond tool.
When cylinder hole finishing is performed with CBN inserts and diamond honing blocks, the fine grinding and honing of the cylinder bores are integrated on one machine to improve machining accuracy and machining efficiency. The boring process uses a PCBN tool, and the honing process uses a single crystal diamond honing block. Both processes use a water soluble coolant.
When the ceramic bond CBN grinding wheel is used for high-speed grinding, the grinding speed currently used is 50-200 m/sec. High-speed grinding plays an important role in the flexible machining of the crankshaft, including the combined grinding of the pin and journal, due to the higher grinding speed and higher machining efficiency. Although high speed grinding is an effective way to increase processing efficiency, the process is still not widely used. The biggest problem facing high speed grinding is the establishment of process technologies that achieve satisfactory levels of reliability and cost.
At different wheel speeds, the relationship between grinding efficiency and tangential grinding force is that the tangential grinding force increases as the level of grinding efficiency increases, and the rate of increase depends on the wheel speed. The normal grinding force also shows the same trend. In other words, when the grinding wheel speed is high, the rate of increase of the grinding force is small. We apply this feature to the production line and perform ultra-high speed cam grinding at a grinding speed of 200 m/s. If the performance of the grinding wheel for high-speed grinding can be improved, it is possible to further expand its application range.
Latest research topics in diamond and CBN tooling technology
The test results obtained by high-efficiency precision turning of aluminum alloy by single crystal diamond (SCD) scraping blade show that the surface roughness is a function of the tool radius and the feed rate. When the radius of the tool nose is greater than 10 mm, a surface roughness of less than Ra of 0.1 μm can be obtained; at a high feed rate of 0.4 mm/rev, a tool having a radius of a large tool nose can be used to obtain a surface of Ra 0.1 μm. Roughness. These test results show that the process can increase the surface roughness by an order of magnitude while achieving the same high processing efficiency as conventional processing methods.
Test results obtained by precision hard turning with CBN inserts show that surface roughness is a function of feed rate. In this test, the surface roughness of Ra 0.03 μm was obtained by grinding the cutting edge of the cutter. An application example of machining a toroidal continuously variable transmission (CVT) disc with this technique shows that hard turning can replace conventional grinding and then final finishing of the disc with superfinishing.
The test results obtained by intermittently cutting hardened steel with CBN tools in the machining of the teeth indicate that the tool with the inclined cutting edge feeds in the tangential direction toward the workpiece during the machining of the teeth. In conventional machining with a cutting speed of 300 m/min, the tool breaks shortly after the start of the cutting process. In contrast, in the machining of the teeth using the CBN tool, the tool life calculated by the cutting length reached about 15 km. This result indicates that the tooth process can achieve efficient interrupted cutting of hardened steel.
Some of the research results on ultra-high speed grinding are described below. The relationship between the grinding efficiency and the surface roughness of some typical grinding methods indicates that the grinding efficiency tends to decrease as the surface roughness decreases with conventional grinding processes. Therefore, we have adopted a grinding wheel truncation to improve the surface roughness. In addition, we have invented a new concept of high-speed grinding and ultra-high-speed grinding as a way to further improve grinding efficiency. In this way, we strive to achieve a mirror-like surface grinding effect while achieving a higher level of grinding efficiency that was previously difficult to obtain.
The first application example is the use of a ceramic bond CBN grinding wheel for ultra-high speed grinding with ultra-high grinding wheels and workpiece speeds. In peripheral grinding with a grinding wheel speed of 240 m/s, the machined surface roughness is used as a function of the feed rate. Comparing the surface roughness values ​​at the general workpiece speed (40 m/min) and the high workpiece speed (520 m/min), the results show that even at a high workpiece speed of 520 m/min, the feed rate (ie, machining efficiency) is increased by 4 Above the surface, the surface roughness did not change substantially, and no white etching layer was observed on the cross-sectional micrograph. In other words, these results show that efficient machining can be achieved by simultaneously increasing the speed of the grinding wheel and the speed of the workpiece.
A second application example is the efficient grinding of mirror-like surfaces using ceramic bond CBN grinding wheels. The ratio of the machined surface roughness as a ratio of the dressing speed. When a large dressing lead of 0.1 mm/rev is used, the surface roughness value increases as the ratio of the dressing speed increases. On the contrary, when the small trimming lead of 0.01 mm/rev was used, the surface roughness was not significantly deteriorated. The photomicrograph shows the work-affected layer when the dressing lead is set to 0.01 mm/rev and the dressing speed ratio is 0.2 and 0.8, respectively. When the ratio of the dressing speed is 0.2, the white etching layer and the tempering layer can be observed; and when the ratio of the trimming speed is 0.8, these metamorphic layers are very small and hardly recognized. By applying this grinding technology, it is expected that mirror-like surface grinding of crankshafts and other parts can be achieved, and the same processing efficiency as conventional grinding methods can be obtained.
Future prospects for diamond and CBN tools
The two main foundations of the development strategy related to the automotive industry and processing technology are globalization and the development of new products and technologies. These two foundations will continue to evolve with the advancement of parent technologies such as machine tool technology, tool technology and other technologies. In order to remain competitive in the near future, companies will need to adapt to the evolving global processing technology. In order to achieve future growth, companies must develop processing technologies for the production of new products and have the resources to implement these technologies on a global scale. In order to expand the market for diamond and CBN tools, there is a need for development strategies that are associated with this technological advancement.
One question is: How big is the expansion space in the global market? Forecasts for global car ownership in the next few years estimate that car ownership in 2020 will be about 1.3 times higher than current levels. In Europe, North America, Japan and other mature automotive markets, car penetration has exceeded one car per two people. At present, the global car penetration rate is about one car per ten people. This data shows that the global automotive market will continue to grow in the coming years. In other words, a development strategy for diamond and CBN tooling technology needs to be developed to address this global growth in automotive demand.
In predicting the future of diamond and CBN tools, let's shift the perspective of considering the problem from quantitative growth to application expansion. Predictions of diamond and CBN tools related to changes in the materials of major components of automotive power systems indicate that aluminum, manganese and other light alloys, as well as titanium alloys, sintered alloys and other high-strength alloys, will increasingly be used as power system zeros in the future. The material of the part. Therefore, diamond tools capable of processing these materials are expected to have a very large increase.
Forecasts for future automotive technology developments indicate that automotive technology will evolve from current gasoline and diesel engines to motor-assisted, hybrid, and then further developed into fuel cell stacks. It will therefore be necessary to develop new diamond and CBN tooling technologies associated with this change.
According to forecasts, the short-term growth and medium- and long-term growth of automakers will continue to be optimistic. The author believes that it can be expected that diamond and CBN tool processing technology will be further developed by keeping up with the development trend of automotive technology and expanding the scope of processing applications. The author describes some trends in the automotive industry and introduces relevant diamond and CBN tool processing techniques from the perspective of automakers. It is hoped that the automotive industry and the diamond and CBN tool industry will continue to work together and develop together in the future.
Author: Zhang Xian compilation
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