US20090056400A1 - Method and apparatus for producing stepped hollow shafts or stepped cylindrical hollow members by transverse rolling - Google Patents
Method and apparatus for producing stepped hollow shafts or stepped cylindrical hollow members by transverse rolling Download PDFInfo
- Publication number
- US20090056400A1 US20090056400A1 US12/202,018 US20201808A US2009056400A1 US 20090056400 A1 US20090056400 A1 US 20090056400A1 US 20201808 A US20201808 A US 20201808A US 2009056400 A1 US2009056400 A1 US 2009056400A1
- Authority
- US
- United States
- Prior art keywords
- workpiece
- rolling
- rolling tools
- mandrel
- tools
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21H—MAKING PARTICULAR METAL OBJECTS BY ROLLING, e.g. SCREWS, WHEELS, RINGS, BARRELS, BALLS
- B21H1/00—Making articles shaped as bodies of revolution
- B21H1/18—Making articles shaped as bodies of revolution cylinders, e.g. rolled transversely cross-rolling
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/14—Spinning
- B21D22/16—Spinning over shaping mandrels or formers
Definitions
- the invention relates to a method and a device for transversely rolling stepped hollow shafts or cylindrical hollow parts from a pipe.
- pipe blanks for manufacturing divided and undivided pipe stabilisers for motor vehicles can be produced in an advantageous manner. They are characterised by virtue of the fact that they have variable diameters and wall thicknesses in regions over their longitudinal axis, which on the one hand leads to a reduction in component weight and on the other hand permits optimal usage of the installation space available. Furthermore, the load-adapted cross-sections permit a uniform tension distribution and thus optimal usage of the material used.
- further advantages can be achieved by eliminating wall thickness fluctuations in the pipe used and by improving the material quality of the pipe surfaces by stretching any decarburization regions present and so-called “phosphate edges”.
- the blank is axially compressed between wedge-shaped tools with inner forming tools at the same time during the rolling process and is rolled out starting from the centre to form a double-sided cup-shaped hollow body.
- the outer contour of the inner forming tools corresponds to the inner contour of the hollow body.
- the object is achieved in accordance with the invention by virtue of the fact that by means of rolling tools which can be radially advanced and are disposed in a planet-like manner around the workpiece the contour of the transition from a central diameter in one portion of the workpiece to the central diameter in an adjacent portion is rolled by means of co-ordinated control of radial advance of the rolling tools and axial feed of the workpiece and a mandrel head having an outer diameter which is adapted to the smallest inner diameter of the two portions is disposed underneath the rolling tools.
- transitions can also be rolled without the assistance of a mandrel whose outer profile corresponds to the inner profile of the transition.
- the outer periphery of the mandrel head does not lie against the inner periphery of the workpiece at the instantaneous forming site. Only towards the end of this transition and during rolling of continuous portions having a constant inner diameter does the mandrel perform its typical function. For this purpose, it is disposed underneath the rolling tools.
- the friction between the workpiece and the mandrel head is restricted to a minimum. This is achieved on the one hand by a relatively short mandrel head and on the other hand by means of a clearance fit, which is typical for displacement, between the outer and inner diameters of the mandrel head and the workpiece. Moreover, in addition to this clearance a further clearance of at least 0.1 mm is preferably provided which promotes forming and is to be defined as flexing clearance.
- the forming procedure is further assisted by virtue of the fact that the workpiece is mounted in support rollers.
- three support rollers are disposed in each case in one plane in a planet-like manner around the workpiece and are mounted in a stand. They can be radially advanced onto the workpiece.
- the stands are displaceable in parallel with the workpiece axis.
- At least one stand is disposed in a stationary manner in proximity to the rolling tools. Particularly in the case of longer workpieces, at least one further stand is provided which preferably moves simultaneously with the workpiece end, to which it is allocated.
- the support rollers serve to absorb the “transverse forces” which result from the forming procedure and which are not neutralised by the rolling tools and the active part of the rolling mandrel. Such remaining transverse forces also occur primarily during rolling of the transitions. Moreover, they support the weight of the workpiece parts which protrude over the active (engaged) part of the rolling mandrel.
- FIG. 2 shows an enlarged section of FIG. 1
- FIG. 3 shows the section “Z” of FIG. 2 .
- FIGS. 4 a to 4 h show the stepwise formation of a pipe into a hollow shaft.
- the device for transversely rolling stepped hollow shafts from a pipe as shown in FIG. 1 has an approximately cross-shaped outline in the plan view shown in FIG. 1 .
- a rolling spindle drive 4 , a rolling mandrel bearing 7 , a rolling mandrel 8 , the workpiece 1 , support rollers 9 , a clamping device 6 and an axial rolling carriage 5 are disposed in parallel with the axis of the workpiece 1 (the pipe to be formed or the resulting hollow shaft) from right to left.
- Rolling tools 3 are provided at the forming site. They are mounted in radial rolling carriages 2 . These rolling carriages can be displaced transversely with the respect to the workpiece 1 .
- the rolling tools 3 are radially advanced therewith. For this purpose, they have a dedicated, preferably hydraulic, drive.
- the rolling tools 3 are driven about axes in parallel with the workpiece axis by means of the rolling spindle drive 4 .
- the clamping device 6 for clamping the workpiece 1 is located on the axial rolling carriage 5 .
- the forces for pulling the workpiece 1 are applied against the rolling tools 3 by two hydraulic pistons which are disposed in a pivotable manner in the axial rolling carriage 5 .
- FIGS. 4 a to 4 h illustrate the sequence of forming a hollow shaft which has multiple steps in its central part.
- the workpiece 1 is clamped in the clamping device 6 and is pulled the distance of a feeding path s ax .
- the rolling tools 3 are advanced radially by the distance s r .
- the respective path length is indicated by the length of the arrow.
- the direction is given by + and ⁇ .
- + in the drawing denotes the movement to the left (in the direction of tension of the clamping device 6 ).
- the radial advance of the rolling tools in the direction of the workpiece axis is denoted by +, and the opposite direction is denoted by ⁇ .
- Rolling mandrels 8 a to 8 c which have an outer diameter corresponding to the respective smallest inner diameter of the workpiece are used. The mandrel head has not been illustrated.
- FIG. 4 b a first transition from the previous diameter to a smaller central diameter is rolled.
- the rolling tools 3 are advanced with +s r .
- the workpiece 1 is pulled the distance of a small axial feed path.
- the large diameter mandrel 8 a is disposed underneath the forming site. At the beginning of the transition, the inner periphery of the workpiece 1 is not yet supported by the mandrel 8 b.
- steps 4 d and 4 e further step-formation similar to that performed in steps 4 b and 4 c is carried out but with the medium diameter rolling mandrel 8 b.
- FIGS. 4 f and 4 g illustrate on the one hand a repetition of the above-described forming steps with the smallest diameter rolling mandrel 8 c .
- a feature of FIG. 4 g is that a conical transition is rolled.
- a small axial feed +s ax is coupled with a negative small advance ⁇ s r of the rolling tools.
- the rolling mandrel is still located underneath the rolling tools 3 but at the instantaneous forming site is still only in radial proximity to the inner periphery of the workpiece 1 .
- FIG. 4 h the hollow shaft is completely rolled.
- the rolling tools are disengaged.
Abstract
Description
- The invention relates to a method and a device for transversely rolling stepped hollow shafts or cylindrical hollow parts from a pipe. In particular, pipe blanks for manufacturing divided and undivided pipe stabilisers for motor vehicles can be produced in an advantageous manner. They are characterised by virtue of the fact that they have variable diameters and wall thicknesses in regions over their longitudinal axis, which on the one hand leads to a reduction in component weight and on the other hand permits optimal usage of the installation space available. Furthermore, the load-adapted cross-sections permit a uniform tension distribution and thus optimal usage of the material used. When utilising the invention for the pipe-stabiliser application, further advantages can be achieved by eliminating wall thickness fluctuations in the pipe used and by improving the material quality of the pipe surfaces by stretching any decarburization regions present and so-called “phosphate edges”.
- Various solutions for transversely rolling stepped hollow shafts or hollow bodies or cup-shaped hollow parts over a mandrel are already known.
- In accordance with DD 99 521 A or even DE 199 05 038 A1, the blank is axially compressed between wedge-shaped tools with inner forming tools at the same time during the rolling process and is rolled out starting from the centre to form a double-sided cup-shaped hollow body. The outer contour of the inner forming tools (mandrels) corresponds to the inner contour of the hollow body.
- In the broadest sense, the solutions for rolling bearing seats and outer toothings (EP 0 248 983 A1 or DE 199 58 343 A1) or inner toothings (e.g. U.S. Pat. No. 5,765,419) are classified in this group of transverse rolling with profiled mandrels or transverse rolling tools.
- Longer hollow shafts are reduced substantially only in wall thickness on a continuously cylindrical mandrel, either continuously (WO 02/55226 A1 or DE 20 04 444 C3) or in sections (DE 101 15 815 A1). The last solution is a type of transverse rolling of a stepped hollow shaft. However, only the outer diameter of the hollow shaft is stepped in sections. The inner diameter is unchanged over its entire length and corresponds to the outer diameter of the mandrel.
- In order to produce a pipe-shaped stabiliser for motor vehicles by forming, rotary swaging can be utilised. However, it is not particularly productive in spite of high technical outlay.
- It is the object of the invention to provide a solution with which stepped hollow shafts or cylindrical hollow parts with the most varied dimensions and also longer lengths can be rolled in a flexible manner from a pipe using a small number of simple tools.
- The object is achieved in accordance with the invention by virtue of the fact that by means of rolling tools which can be radially advanced and are disposed in a planet-like manner around the workpiece the contour of the transition from a central diameter in one portion of the workpiece to the central diameter in an adjacent portion is rolled by means of co-ordinated control of radial advance of the rolling tools and axial feed of the workpiece and a mandrel head having an outer diameter which is adapted to the smallest inner diameter of the two portions is disposed underneath the rolling tools.
- It has been found that these transitions can also be rolled without the assistance of a mandrel whose outer profile corresponds to the inner profile of the transition. At the beginning of a transition from a large central diameter to a smaller one, the outer periphery of the mandrel head does not lie against the inner periphery of the workpiece at the instantaneous forming site. Only towards the end of this transition and during rolling of continuous portions having a constant inner diameter does the mandrel perform its typical function. For this purpose, it is disposed underneath the rolling tools.
- Tests have demonstrated that it is possible to produce a pipe-shaped stabiliser for motor vehicles with two regions, which are stepped on the end side, and one long central part, which is reduced in diameter and wall thickness, from a pipe having a length of 1.6 m, ca. 22 mm outer diameter and a wall thickness of ca. 4 mm. The process is very productive. It is fundamentally possible to produce the stabiliser in a clamping system.
- The friction between the workpiece and the mandrel head is restricted to a minimum. This is achieved on the one hand by a relatively short mandrel head and on the other hand by means of a clearance fit, which is typical for displacement, between the outer and inner diameters of the mandrel head and the workpiece. Moreover, in addition to this clearance a further clearance of at least 0.1 mm is preferably provided which promotes forming and is to be defined as flexing clearance.
- The forming procedure is further assisted by virtue of the fact that the workpiece is mounted in support rollers.
- Preferably, three support rollers are disposed in each case in one plane in a planet-like manner around the workpiece and are mounted in a stand. They can be radially advanced onto the workpiece. The stands are displaceable in parallel with the workpiece axis. At least one stand is disposed in a stationary manner in proximity to the rolling tools. Particularly in the case of longer workpieces, at least one further stand is provided which preferably moves simultaneously with the workpiece end, to which it is allocated. Overall, the support rollers serve to absorb the “transverse forces” which result from the forming procedure and which are not neutralised by the rolling tools and the active part of the rolling mandrel. Such remaining transverse forces also occur primarily during rolling of the transitions. Moreover, they support the weight of the workpiece parts which protrude over the active (engaged) part of the rolling mandrel.
- Preferably, the forming procedure is performed using rolling tools which have a smoothing shoulder and a forming shoulder, wherein preferably the free edge of the smoothing shoulder is rounded off with a radius of 0.5 to 3 mm. Primarily, the short transitions are rolled with this edge. In order to roll transitions which on one portion are short on both sides, the workpiece is preferably turned.
- Portions having greater wall thicknesses and consisting of materials which are difficult to form (e.g. high-tensile steels) are heated prior to rolling.
- Further features in accordance with the invention are described in the claims and in the exemplified embodiment.
- The invention will be demonstrated hereinunder in several exemplified embodiments. In the drawings,
-
FIG. 1 shows a plan view of a device in accordance with the invention, -
FIG. 2 shows an enlarged section ofFIG. 1 , -
FIG. 3 shows the section “Z” ofFIG. 2 , -
FIGS. 4 a to 4 h show the stepwise formation of a pipe into a hollow shaft. - The device for transversely rolling stepped hollow shafts from a pipe as shown in
FIG. 1 has an approximately cross-shaped outline in the plan view shown inFIG. 1 . Arolling spindle drive 4, a rolling mandrel bearing 7, arolling mandrel 8, theworkpiece 1,support rollers 9, aclamping device 6 and an axial rollingcarriage 5 are disposed in parallel with the axis of the workpiece 1 (the pipe to be formed or the resulting hollow shaft) from right to left. - Rolling
tools 3 are provided at the forming site. They are mounted in radialrolling carriages 2. These rolling carriages can be displaced transversely with the respect to theworkpiece 1. Therolling tools 3 are radially advanced therewith. For this purpose, they have a dedicated, preferably hydraulic, drive. Therolling tools 3 are driven about axes in parallel with the workpiece axis by means of therolling spindle drive 4. During forming, theworkpiece 1 is pulled with the axial rollingcarriage 5 to the left and at the same time is rotated with therolling tools 3. Theclamping device 6 for clamping theworkpiece 1 is located on the axial rollingcarriage 5. The forces for pulling theworkpiece 1 are applied against therolling tools 3 by two hydraulic pistons which are disposed in a pivotable manner in the axial rollingcarriage 5. - As shown more clearly in
FIG. 2 , acarriage guide 11 is disposed underneath theworkpiece 1. Stands 12 which each have threesupport rollers 9 are disposed in a displaceable manner on this carriage guide. Thesupport rollers 9 surround theworkpiece 1 in a planet-like manner and can be advanced radially onto the respective outer diameter of theworkpiece 1. Thestand 12 a in direct proximity to therolling tools 3 is stationary. The stands 12 b which are further away from therolling tools 3 move with the workpiece 1 (see the double arrow under thestands 12 b). Their spaced interval from therolling tools 3 changes continuously during forming. The movement direction of theworkpiece 1 is shown on the left-hand side by an arrow. - Any remaining transverse forces applied to the
workpiece 1 immediately adjacent to the forming site and in each case at the furthest spaced interval from the forming site are absorbed by thesupport rollers 9. - As shown in
FIG. 3 , the free edge of the smoothing shoulder of the rollingtool 3 is rounded off with a radius r. -
FIGS. 4 a to 4 h illustrate the sequence of forming a hollow shaft which has multiple steps in its central part. - In each case, the
workpiece 1 is clamped in theclamping device 6 and is pulled the distance of a feeding path sax. Therolling tools 3 are advanced radially by the distance sr. The respective path length is indicated by the length of the arrow. The direction is given by + and −. During axial feeding, + in the drawing denotes the movement to the left (in the direction of tension of the clamping device 6). The radial advance of the rolling tools in the direction of the workpiece axis is denoted by +, and the opposite direction is denoted by −.Rolling mandrels 8 a to 8 c which have an outer diameter corresponding to the respective smallest inner diameter of the workpiece are used. The mandrel head has not been illustrated. - In
FIG. 4 a, the workpiece is still the original pipe. It is already clamped.Rolling tools 3 and rolling mandrels are not in engagement. - In
FIG. 4 b, a first transition from the previous diameter to a smaller central diameter is rolled. Therolling tools 3 are advanced with +sr. Theworkpiece 1 is pulled the distance of a small axial feed path. Thelarge diameter mandrel 8 a is disposed underneath the forming site. At the beginning of the transition, the inner periphery of theworkpiece 1 is not yet supported by themandrel 8 b. - In the next step (
FIG. 4 c), the position of therolling tools 3 is no longer radially adjusted. The workpiece is pulled the distance of a relatively long feed path (see arrow size of +sax). - In the steps 4 d and 4 e (cf.
FIGS. 4 d and 4 e), further step-formation similar to that performed in steps 4 b and 4 c is carried out but with the mediumdiameter rolling mandrel 8 b. -
FIGS. 4 f and 4 g illustrate on the one hand a repetition of the above-described forming steps with the smallestdiameter rolling mandrel 8 c. A feature ofFIG. 4 g is that a conical transition is rolled. A small axial feed +sax is coupled with a negative small advance −sr of the rolling tools. The rolling mandrel is still located underneath therolling tools 3 but at the instantaneous forming site is still only in radial proximity to the inner periphery of theworkpiece 1. - In the final stage,
FIG. 4 h, the hollow shaft is completely rolled. The rolling tools are disengaged. - In practical tests, a hollow shaft was rolled from an approximately 1.5 m long pipe consisting of 34MnB5 having an outer diameter of about 25 mm and an wall thickness of about 4 mm. In a central portion (ca. 400 mm long) and at the two ends (ca. 200 mm long), the pipe was stepped by about 2 mm at the outer diameter. The wall thickness of the stepped parts was reduced by about 1 mm. The forming portions were heated. The average rolling temperature was 600° C.
Claims (21)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE102007041149A DE102007041149B3 (en) | 2007-08-30 | 2007-08-30 | Method and device for cross rolling stepped hollow shafts or cylindrical hollow parts from a tube |
DE102007041149.0 | 2007-08-30 |
Publications (1)
Publication Number | Publication Date |
---|---|
US20090056400A1 true US20090056400A1 (en) | 2009-03-05 |
Family
ID=39942038
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/202,018 Abandoned US20090056400A1 (en) | 2007-08-30 | 2008-08-29 | Method and apparatus for producing stepped hollow shafts or stepped cylindrical hollow members by transverse rolling |
Country Status (3)
Country | Link |
---|---|
US (1) | US20090056400A1 (en) |
EP (1) | EP2030703A1 (en) |
DE (1) | DE102007041149B3 (en) |
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20120090372A1 (en) * | 2009-07-09 | 2012-04-19 | Benedikt Nillies | Method and device for stretch-flow forming |
JP2014101136A (en) * | 2012-11-21 | 2014-06-05 | Nisshin Steel Co Ltd | Liquid container of stainless steel |
CN104841821A (en) * | 2015-05-15 | 2015-08-19 | 北京科技大学 | Small-diameter hollow blank transverse rolling precision forming method of mandril control |
JP2018516762A (en) * | 2015-06-10 | 2018-06-28 | 俊 周 | Pipe male thread rolling method, module and equipment and pipe male thread production line |
WO2022122645A1 (en) * | 2020-12-07 | 2022-06-16 | Winkelmann Powertrain Components Gmbh & Co. Kg | Process for manufacturing a rotor shaft |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
PL224268B1 (en) | 2013-06-12 | 2016-12-30 | Lubelska Polt | Method for the rotatry pushing with adjustable wheel base of graded axisymmetric forgings |
CN110102575B (en) * | 2019-04-30 | 2020-07-31 | 北京科技大学 | Two-roller flexible skew rolling forming device and method for shaft parts |
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US3299680A (en) * | 1965-06-10 | 1967-01-24 | Earl A Thompson | Rolling machine for forming tubular workpieces |
US4554810A (en) * | 1984-04-02 | 1985-11-26 | Motor Wheel Corporation | Draw-spinning of integral vehicle wheel rim and disc segments |
US4669291A (en) * | 1984-12-19 | 1987-06-02 | Kabushiki Kaisha Kobe Seiko Sho | Spinning type multiple roller forming machine |
US5323630A (en) * | 1993-02-19 | 1994-06-28 | Leifeld Gmbh & Co. | Flow-roller machine |
US5384949A (en) * | 1993-01-05 | 1995-01-31 | General Motors Corporation | Torque transmitting structure and method of manufacture |
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US7168284B2 (en) * | 2004-07-20 | 2007-01-30 | Minako Matsuoka | Method and apparatus for producing hollow rack bar and mandrel used for rack bar production |
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2007
- 2007-08-30 DE DE102007041149A patent/DE102007041149B3/en not_active Expired - Fee Related
-
2008
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- 2008-08-29 US US12/202,018 patent/US20090056400A1/en not_active Abandoned
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US3299680A (en) * | 1965-06-10 | 1967-01-24 | Earl A Thompson | Rolling machine for forming tubular workpieces |
US4554810A (en) * | 1984-04-02 | 1985-11-26 | Motor Wheel Corporation | Draw-spinning of integral vehicle wheel rim and disc segments |
US4669291A (en) * | 1984-12-19 | 1987-06-02 | Kabushiki Kaisha Kobe Seiko Sho | Spinning type multiple roller forming machine |
US5384949A (en) * | 1993-01-05 | 1995-01-31 | General Motors Corporation | Torque transmitting structure and method of manufacture |
US5323630A (en) * | 1993-02-19 | 1994-06-28 | Leifeld Gmbh & Co. | Flow-roller machine |
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US20040065129A1 (en) * | 2000-08-14 | 2004-04-08 | Leico Gmbh & Co. Werkzeugmaschinenbau | Method for forming a groove and flow-forming machine |
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US7131305B2 (en) * | 2003-10-17 | 2006-11-07 | Delphi Technologies, Inc. | Method and apparatus for lean spin forming |
US7168284B2 (en) * | 2004-07-20 | 2007-01-30 | Minako Matsuoka | Method and apparatus for producing hollow rack bar and mandrel used for rack bar production |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20120090372A1 (en) * | 2009-07-09 | 2012-04-19 | Benedikt Nillies | Method and device for stretch-flow forming |
US8997541B2 (en) * | 2009-07-09 | 2015-04-07 | Leifeld Metal Spinning Ag | Method and device for stretch-flow forming |
JP2014101136A (en) * | 2012-11-21 | 2014-06-05 | Nisshin Steel Co Ltd | Liquid container of stainless steel |
CN104841821A (en) * | 2015-05-15 | 2015-08-19 | 北京科技大学 | Small-diameter hollow blank transverse rolling precision forming method of mandril control |
JP2018516762A (en) * | 2015-06-10 | 2018-06-28 | 俊 周 | Pipe male thread rolling method, module and equipment and pipe male thread production line |
WO2022122645A1 (en) * | 2020-12-07 | 2022-06-16 | Winkelmann Powertrain Components Gmbh & Co. Kg | Process for manufacturing a rotor shaft |
Also Published As
Publication number | Publication date |
---|---|
EP2030703A1 (en) | 2009-03-04 |
DE102007041149B3 (en) | 2009-04-02 |
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