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Improved method of gear hobbing computer aided simulation

Ihor Hrytsay Vadym Stupnytskyy Vladyslav Topchii
Archive of Mechanical Engineering | 2019 | vol. 66 | No 4 | 475-494 | DOI: 10.24425/ame.2019.131358
Keywords gear hobbing cutting process simulation kinematics of cutting
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Abstract

Simulation studies of the hobbing process kinematics can effectively improve the accuracy of the machined gears. The parameters of the cut-off layers constitute the basis for predicting the cutting forces and the workpiece stress-strain state. Usually applied methods for simulation of the hobbing process are based on simplified cutting schemes. Therefore, there are significant differences between the simulated parameters and the real ones. A new method of hobbing process modeling is described in the article. The proposed method is more appropriate, since the algorithm for the momentary transition surfaces formation and computer simulation of the 3D chip cutting sections are based on the results of hobbing cutting processes kinematics and on rheological analysis of the hob cutting process formation. The hobbing process is nonstationary due to the changes in the intensity of plastic strain of the material. The total cutting force is represented as a function of two time-variable parameters, such as the chip’s 3D parameters and the chip thickness ratio depending on the parameters of the machined layer.

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Bibliography

[1] V. Dimitriou and A. Antoniadis. CAD-based simulation of the hobbing process for the manufacturing of spur and helical gears. The International Journal of Advanced Manufacturing Technology, 41(3-4):347–357, 2009. doi: 10.1007/s00170-008-1465-x.
[2] V. Dimitriou, N. Vidakis, and A. Antoniadis. Advanced computer aided design simulation of gear hobbing by means of three-dimensional kinematics modeling. Journal of Manufacturing Science and Engineering, 129(5):911–918, 2007. doi: 10.1115/1.2738947.
[3] K.-D. Bouzakis, S.Kombogiannis, A. Antoniadis, andN.Vidakis. Gear hobbing cutting process simulation and toolwear prediction models. Journal of Manufacturing Science and Engineering, 124(1):42–51, 2001. doi: 10.1115/1.1430236.
[4] J. Edgar. Hobs and Gear Hobbing: A Treatise on the Design of Hobs and Investigation into the Conditions Met with Gear Hobbing. Forgotten Books, 2015.
[5] N. Sabkhi, C. Pelaingre, C. Barlier, A. Moufki, and M. Nouari. Characterization of the cutting forces generated during the gear hobbing process: Spur gear. Procedia CIRP, 31:411–416, 2015. doi: 10.1016/j.procir.2015.03.041.
[6] W. Liu, D. Ren, S.Usui, J.Wadell, and T.D.Marusich. A gear cutting predictive model using the finite element method. Procedia CIRP, 8:51–56, 2013. doi: 10.1016/j.procir.2013.06.064.
[7] N. Tapoglou, T. Belis, Taxiarchis, D. Vakondios, and A. Antoniadis. CAD-based simulation of gear hobbing. In Proceeding of 31st International Symposium on Mechanics and Materials, volume 1, pages 41–57, Agia Marina, Greece. 9-14 May, 2010.
[8] C. Brecher, M. Brumm, and M. Krömer. Design of gear hobbing processes using simulations and empirical data. Procedia CIRP, 33:484-489, 2015. doi: 10.1016/j.procir.2015.06.059.
[9] G. Sulzer. Increased performance in gears production by accurate detection of machining kinematics. Ph.D. Thesis, RWTH Aachen University, Aachen, Germany, 1974 (in German).
[10] P. Gutman. Machining force calculation during hobbing. Ph.D. Thesis, RWTH Aachen University, Aachen, Germany, 1988 (in German).
[11] X. Dong, C. Liao, Y.C. Shin, and H.H. Zhang. Machinability improvement of gear hobbing via process simulation and tool wear predictions. The International Journal of Advanced Manufacturing Technology, 86(9-12):2771–2779, 2016. doi: 10.1007/s00170-016-8400-3.
[12] V. Sinkevicius. Simulation of gear hobbing forces. Kaunas University of Technology Journal: Mechanika, 2(28):58–63, 2001.
[13] I. Hrytsay. Simulation of cross-sections, forces and torques during gear machining by hobs. Mashynoznavstvo, 7:19–23, 1998 (In Ukrainian).
[14] I. Hrytsay andV. Sytnik. Force field of screw-type toothing cutter and its quantitative evaluation. Optimization and Technical Control in Engineering and Instrumentation, 371:3–13, 1999 (In Ukrainian).
[15] V. Stupnytskyy. Features of functionally-oriented engineering technologies in concurrent environment. International Journal of Engineering Research and Technology, 2(9):1181–1186, 2013.
[16] V. Stupnytskyy. Thermodynamic pattern of the workpiece machining by the rheological imitation modelling in deform-3D system. O ptimization and Technical Control in Engineering and Instrumentation, 772:102–114, 2013.
[17] V. Stupnytskyy. Computer aided machine-building technological process planning by the methods of concurrent engineering. Europaische Fachhochschule: Wissenschaftliche Zeitschrift, ORT Publishing, 2:50–53, 2013.
[18] N. Sabkhi, A. Moufki, M. Nouari, C. Pelaingre, and C. Barlier. Prediction of the hobbing cutting forces from a thermomechanical modeling of orthogonal cutting operation. J ournal of Manufacturing Processes, 23:1–12, 2016. doi: 10.1016/j.jmapro.2016.05.002.
[19] F. Klocke. Manufacturing Processes 1: Cutting. Springer, 2011.
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Authors and Affiliations

Ihor Hrytsay
1
Vadym Stupnytskyy
1
Vladyslav Topchii
1
  1. Department of Mechanical Engineering Technologies, Institute of Engineering Mechanics and Transport, Lviv Polytechnic National University, Lviv, Ukraine.

Identification of Data Affected by Aberrant Errors in the Study of the Milling Process on Aluminum Alloys

Mihail Aurel Țîțu A.B. Pop
Archives of Metallurgy and Materials | 2023 | vol. 68 | No 2 | 525-530 | DOI: 10.24425/amm.2023.142431
Keywords cutting process surface roughness aberrant error Romanovki test
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Abstract

In this scientific paper it is presented the statistical analysis of the experimental data obtained by the study of the influence of the cutting parameters exerted in end-milling process on the surface roughness. The surface roughness parameter is measured in the cutting feed direction and against it. The parameters of the cutting process, the number of levels and their values were established. Based on these parameters, the research was designed on a complete factorial experiment, randomized with seven blocks. The surface roughness values were measured using a roughness tester. The research method used involved the Romanovski test. The aim of this test was to identify the data affected by aberrant errors, to remove them from the samples and then to repeat the tests for the remaining data strings until all values met the conditions imposed by the test.
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Authors and Affiliations

Mihail Aurel Țîțu
ORCID: ORCID
A.B. Pop
1
ORCID: ORCID
  1. Technical University of Cluj-Napoca, Northern University Centre of Baia Mare, Faculty of Engineering – Department of Engineering and Technology Management, 62A, Victor Babes Street, 430083, Baia Mare, Maramures, Romania

Simulation of loading and wear rate distribution on cutting edges during gears hobbing

Ihor Hrytsay Vadym Stupnytskyy Vladyslav Topchi
Archive of Mechanical Engineering | 2021 | vol. 68 | No 1 | 52-76 | DOI: 10.24425/ame.2021.137041
Keywords gear hobbing cutting process simulation wear resistance friction
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Abstract

Results of complex mathematical and computer simulation of gear hobbing are given. A systematic approach to research allowed for the development of simulation models and sequencing of all aspects of this complex process. Based on the modeling of non-deformable chips, a new analytical method for analyzing hobbing has been proposed. The shear, friction and cutting forces at the level of certain teeth and edges in the active space of the cutter are analyzed depending on the cut thickness, cross-sectional area, intensity of plastic deformation and length of contact with the workpiece has been developed. The results of computer simulations made it possible to evaluate the load distribution along the cutting edge and to predict the wear resistance and durability of the hob cutter, as well as to develop measures and recommendations for both the tool design and the technology of hobbing in general. Changing the shape of cutting surface, or the design of the tooth, can facilitate separation of the cutting process between the head and leading and trailing edges. In this way, more efficient hobbing conditions can be achieved and the life of the hob can be extended.
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Bibliography

[1] B. Karpuschewski, H.J. Knoche, M. Hipke, and M. Beutner. High performance gear hobbing with powder-metallurgical high-speed-steel. In Procedia CIRP, 1:196–201, 2012. doi: 10.1016/j.procir.2012.04.034.
[2] B. Karpuschewski, M. Beutner, M. Köchig, and C. Härtling. Influence of the tool profile on the wear behaviour in gear hobbing. CIRP Journal of Manufacturing Science and Technology, 18:128–134, 2018. doi: 10.1016/j.cirpj.2016.11.002.
[3] K.-D. Bouzakis, O. Friderikos, I. Mirisidis, and I. Tsiafis. Geometry and cutting forces in gear hobbing by a FEM-based simulation of the cutting process. In Proceedings of the 8th CIRP International Workshop on Modeling of Machining Operations, 10-11 May, Chemnitz, 2005.
[4] F. Klocke, C. Gorgels, R. Schalaster, and A. Stuckenberg. An innovative way of designing gear hobbing processes. Gear Technology, May:48–53, 2012.
[5] K.D. Bouzakis, S. Kombogiannis, A. Antoniadis, and N. Vidakis. Gear hobbing cutting process simulation and tool wear prediction models. Journal of Manufacturing Science and Engineering, 124(1):42–51, 2002. doi: 10.1115/1.1430236.
[6] K.D. Bouzakis, E. Lili E, N. Michailidis, and O. Friderikos. Manufacturing cylindrical gears by generating cutting processes: a critical synthesis of analysis methods. CIRP Annals, 57(2):676–696, 2008. doi: 10.1016/j.cirp.2008.09.001.
[7] G. Skordaris, K.D. Bouzakis, T. Kotsanis, P. Charalampous, E. Bouzakis, O. Lemmer, and S. Bolz. Film thickness effect on mechanical properties and milling performance of nano-structured multilayer PVD coated tools. Surface and Coatings Technology, 307, Part A:452–460, 2016, doi: 10.1016/j.surfcoat.2016.09.026.
[8] K.D. Bouzakis, S. Kombogiannis, A. Antoniadis, and N. Vidakis. Modeling of gear hobbing. Cutting simulation, tool wear prediction models and computer supported experimental-analytical determination of the hob life-time. In Proceeding of ASME International Mechanical Engineering Congress and Exposition, volume 1, pages 261–269, Shannon, 14–19 November, 1999.
[9] N. Sabkhi, A. Moufki, M. Nouari, C. Pelaingre, and C. Barlier. Prediction of the hobbing cutting forces from a thermomechanical modeling of orthogonal cutting operation. Journal of Manufacturing Processes, 23:1–12, 2016. doi: 10.1016/j.jmapro.2016.05.002.
[10] V. Dimitriou and A. Antoniadis. CAD-based simulation of the hobbing process for the manufacturing of spur and helical gears. The International Journal of Advanced Manufacturing Technology, 41(3-4):347–357, 2009. doi: 10.1007/s00170-008-1465-x.
[11] C. Claudin and J. Rech. Effects of the edge preparation on the tool life in gear hobbing. In Proceedings of the 3rd International Conference on Manufacturing Engineering (ICMEN), pages 57-70, Chalkidiki, Greece, 1-3 October 2008.
[12] J. Rech. Influence of cutting edge preparation on the wear resistance in high speed dry gear hobbing. Wear, 261(5-6):505–512, 2006. doi: 10.1016/j.wear.2005.12.007.
[13] C. Claudin and J. Rech. Development of a new rapid characterization method of hob’s wear resistance in gear manufacturing – Application to the evaluation of various cutting edge preparations in high speed dry gear hobbing. Journal of Materials Processing Technology, 209(11):5152–5160, 2009. doi: 10.1016/j.jmatprotec.2009.02.014.
[14] B. Hoffmeister. Über den Verschleiß am Wälzfräser (About wear on the hob). D.Sc. Thesis, RWTH Aachen, Germany, 1970 (in German).
[15] V.P. Astakhov. Metal Cutting Mechanics. CRC Press, 1999.
[16] P. Gutmann. Zerspankraftberechnung beim Waelzfraesen (Calculation of the cutting force for hobbing). Ph.D. Thesis, RWTH Aachen University, Aachen, Germany, 1988 (in German).
[17] I. Hrytsay, V.Stupnytskyy, and V. Topchii. Improved method of gear hobbing computer aided simulation. Archive of Mechanical Engineering, 66(4):475–494, 2019. doi: 10.24425/ame.2019.131358.
[18] V. Stupnytskyy and I. Hrytsay. Computer-aided conception for planning and researching of the functional-oriented manufacturing process. In: Tonkonogyi V. et al. (eds) Advanced Manufacturing Processes. InterPartner-2019. Lecture Notes in Mechanical Engineering, pages 309–320, 2020. doi: 10.1007/978-3-030-40724-7_32.
[19] I. Hrytsay and V. Stupnytskyy. Advanced computerized simulation and analysis of dynamic processes during the gear hobbing. In: Tonkonogyi V. et al. (eds) Advanced Manufacturing Processes. InterPartner-2019. Lecture Notes in Mechanical Engineering, pages 85–97, 2019. doi: 10.1007/978-3-030-40724-7_9.
[20] S.S. Silin. Similarity Methods in Metal Cutting, Mashinostroenie, Moscow, 1979. (in Russian).
[21] S.P. Radzevich. Gear Cutting Tools. Science and Engineering. CRC Press, 2017.
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Authors and Affiliations

Ihor Hrytsay
1
ORCID: ORCID
Vadym Stupnytskyy
1
ORCID: ORCID
Vladyslav Topchi
1
ORCID: ORCID
  1. Lviv Polytechnic National University, Lviv, Ukraine

Research on Disc Cutting Unit for Cutting Energy Plants

Henryk Rode Marcin Chęciński
Teka Commission of Motorization and Power Industry in Agriculture | 2016 | vol. 16 | No 1
Keywords cutting process energy plants unitary energy of cutting moisture rotary speed of cutting unit basket willow
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Abstract

The paper presents the results of laboratory tests concerning the cutting process of basket willow by means of disc cutting unit. A disc for cutting wood with diameter of 600mm was used in the tests. The influence of plant’s moisture and the rotary speed of the disc of cutting unit on the unitary energy were determined. The most favorable values of the operating parameters of the cutting unit were selected according to the minimum energy requirement in the cutting process of the tested plant.
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Authors and Affiliations

Henryk Rode
Marcin Chęciński

The advantage of using the microcontroller PIC18F4455 as a control tool for a band saw

Józef Wojnarowski Bohdan Borowik
Archive of Mechanical Engineering | 2008 | vol. 55 | No 3 | 237-245 | DOI: 10.24425/ame.2008.131624
Keywords cutting process endless band saw pump hydraulic control systems pulse train
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Abstract

The paper describes a system that utilizes a microprocessor in controlling the clamping force of the band saw teeth against the cutting metals. This control system allows the blades to operate more efficiently, and prolongs the blade life. It also has an influence on the removal of chips from the blade and maintains a constant strength over the blade. The system can operate in the vertical and horizontal position. A highly advanced and powerful microcontroller PIC18F4455 is programmed to operate with feedback from 4 sensors. Additionally system requires the parametrical data on the shape, the profile and the kind of material to be cut, for adjustment the process of cutting. Feedback control is implemented via a collocated force actuator/rate sensors. The control theory is used to develop controllers, which achieve robust stability.

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Authors and Affiliations

Józef Wojnarowski
Bohdan Borowik

Hob wear prediction based on simulation of friction, heat fluxes, and cutting temperature

Ihor Hrytsay Vadym Stupnytskyy
Archive of Mechanical Engineering | 2023 | vol. 70 | No 2 | 271-286 | DOI: 10.24425/ame.2023.145582
Keywords gear hobbing cutting process simulation wear resistance heat fluxes cutting temperature
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Abstract

Based on comprehensive interrelated mathematical and graphical-analytical models, including 3D cut layers and simulation of contact, strain, force, and thermal processes during gear hobbing friction forces, heat fluxes, and temperature on the teeth of the hob surface are investigated. Various physical phenomena are responsible for their wear: friction on contact surfaces and thermal flow. These factors act independently of each other; therefore, the worn areas are localized in different active parts of the hob. Friction causes abrasive wear and heat fluxes result in heat softening of the tool. Intense heat fluxes due to significant friction, acting on areas of limited area, lead to temperatures exceeding the critical temperature on certain edges of the high-speed cutter. Simulation results enable identification of high-temperature areas on the working surface of cutting edges, where wear is caused by various reasons, and make it possible to select different methods of hardening these surfaces. To create protective coatings with maximum heat resistance, it is advisable to use laser technologies, electro spark alloying, or plasma spraying, and for coatings that provide reduction of friction on the surfaces – formation of diamond-containing layers with minimum adhesion properties and low friction coefficient on the corresponding surfaces.
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Bibliography

1. K.-D. Bouzakis, S. Kombogiannis, A. Antoniadis, and N. Vidakis. Gear hobbing cutting process simulation, and tool wear prediction models. Journal of Manufacturing Science and Engineering, 124(1):42–51, 2002. doi: 10.1115/1.1430236.
2. V. Dimitriou, N. Vidakis, and A Antoniadis. Advanced computer aided design simulation of gear hobbing by means of three-dimensional kinematics modeling. Journal of Manufacturing Science and Engineering, 129(5):911–918, 2007. doi: 10.1115/1.2738947.
3. S.P. Radzevich, and M. Storchak. Advances in Gear Theory and Gear Cutting Tool Design. Springer, Cham, Switzerland, 2022.
4. I. Hrytsay, V. Stupnytskyy, and V. Topchii. Improved method of gear hobbing computer aided simulation. Archive of Mechanical Engineering, 66(4):475–494, 2019. doi: 10.24425/ame.2019.131358.
5. S. Stein, M. Lechthaler, S. Krassnitzer, K. Albrecht, A. Schindler, and M. Arndt. Gear hobbing: a contribution to analogy testing, and its wear mechanisms. Procedia CIRP, 1:220–225, 2012. doi: 10.1016/j.procir.2012.04.039.
6. X. Yang and P. Chen. Heat transfer enhancement strategies for eco-friendly dry hobbing considering the heat exchange capacity of chips. Case Studies in Thermal Engineering, 29, 101716, 2022. doi: 10.1016/j.csite.2021.101716.
7. H. Cao, L. Zhu, X. Li, P. Chen, and Y. Chen. Thermal error compensation of dry hobbing machine tool considering workpiece thermal deformation. International Journal of Advanced Manufacturing Technology, 86:1739–1751, 2016. doi: 10.1007/s00170-015-8314-5.
8. T. Tezel, E.S. Topal, and V. Kovan. Characterising the wear behaviour of DMLS-manufactured gears under certain operating conditions. Wear, 440–441:203106, 2019. doi: 10.1016/j.wear.2019.203106.
9. S. Stark, M. Beutner, F. Lorenz, S. Uhlmann, B. Karpuschewski, and T. Halle. Heat flux, and temperature distribution in gear hobbing operations. Procedia CIRP, 8:456–461, 2013. doi: 10.1016/j.procir.2013.06.133.
10. N. Tapoglou, T. Belis, D. Vakondios, and A. Antoniadis. CAD-based simulation of gear hobbing. 31 International Symposium on Mechanics, and Materials, May 9–14, Greece, 2010.
11. K.D. Bouzakis, K. Chatzis, S. Kombogiannis, and O. Friderikos. Effect of chip geometry, and cutting kinematics on the wear of coated PM HSS tools in milling. Proceedings of the 7th International Conference Coatings in Manufacturing Engineering, pages 197–208, 1–3 October, Chalkidiki, Greece. 2008.
12. K.-D. Bouzakis, E. Lili, N. Michailidis, and O. Friderikos. Manufacturing of cylindrical gears by generating cutting processes: A critical synthesis of analysis methods. CIRP Annals, 57(2):676–696, 2008. doi: 10.1016/j.cirp.2008.09.001.
13. B. Karpuschewski, H.J. Knoche, M. Hipke, and M. Beutner. High performance gear hobbing with powder-metallurgical high-speed-steel. Procedia CIRP, 1:196–201, 2012. doi: 10.1016/j.procir.2012.04.034.
14. B. Karpuschewski, M. Beutner, M. Köchig, and C. Härtling. Influence of the tool profile on the wear behaviour in gear hobbing. CIRP Journal of Manufacturing Science and Technology, 18:128–134, 2018. doi: 10.1016/j.cirpj.2016.11.002.
15. F. Klocke, C. Gorgels, R. Schalaster, and A. Stuckenberg. An innovative way of designing gear hobbing processes. Gear Technology, 1:48–53, 2012.
16. C. Claudin, and J. Rech. Effects of the edge preparation on the tool life in gear hobbing. In Proceedings of the 3rd International Conference on Manufacturing Engineering (ICMEN), pages 57–70, Chalkidiki, Greece, 1–3 October 2008.
17. J. Rech. Influence of cutting edge preparation on the wear resistance in high speed dry gear hobbing. Wear, 261(5-6):505–512, 2006. doi: 10.1016/j.wear.2005.12.007.
18. C. Claudin, and J. Rech. Development of a new rapid characterization method of hob’s wear resistance in gear manufacturing – Application to the evaluation of various cutting edge preparations in high speed dry gear hobbing. Journal of Materials Processing Technology, 209(11):5152–5160, 2009. doi: 10.1016/j.jmatprotec.2009.02.014.
19. B. Hoffmeister. About Wear on the Hob. D.Sc. Thesis, RWTH Aachen, Germany, 1970 (in German).
20. I. Hrytsay, and V. Stupnytskyy. Prediction the durability of hobs based on contact, and friction analysis on the faces for cutting teeth, and edges during hobbing. In: V. Ivanov, J. Trojanowska, I. Pavlenko, J. Zajac, D. Peraković (eds): Advances in Design, Simulation and Manufacturing IV. Lecture Notes in Mechanical Engineering. Springer, 1:405–414, 2021. doi: 10.1007/978-3-030-77719-7_40.
21. F. Klocke. Manufacturing Processes, Cutting. Springer, RWTH edition, 2011.
22. M.P. Mazur, V.M. Vnukov, V.L. Dobroskok, V.O. Zaloga, J.K. Novosiolov, and F.J. Yakubov. Fundamentals of the Theory of Cutting Materials. Novyy Svit, 2011 (in Ukrainian).
23. I. Hrytsay, V. Stupnytskyy, and V. Topchii. Simulation of loading, and wear rate distribution on cutting edges during gears hobbing. Archive of Mechanical Engineering, 68(1):52–76, 2021. doi: 10.24425/ame.2021.137041.
24. A.B. Aleksandrovich, B.D. Danilenko, Y.V. Loshchinin, T.A. Kolyadina, and I.M. Khatsinskaya. Thermophysical properties of low-alloy high-speed steels. Metal Science and Heat Treatment, 30:502–504, 1988. doi: 10.1007/BF00777438.
25. N.G. Abuladze. Character, and the length of tool–chip contact. In Proceedings of the Machinability of Heat-Resistant and Titanium Alloys, pages 68–78, Kuibyshev, S.U., 1962. (in Russian)..
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Authors and Affiliations

Ihor Hrytsay
1
ORCID: ORCID
Vadym Stupnytskyy
1
ORCID: ORCID
  1. Lviv Polytechnic National University, Lviv, Ukraine

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