Zhejiang Balford Mechatronics Co., ltd focus on difficult stamping & deep drawing. Main product: motor housing and difficult custom deep drawn stampings.
Congratulations! Junhao Stampings Company, one division of Balford Mechatronics Co.,Ltd. got order for motor housing from Unimotor in 2014, which means starting the long-term cooperation with this world's first-class automobile motor provider. Unimotor, a Four Seasons company and ...
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Compared with steel parts, the forming process of aluminum parts is more prone to necking and cracking. There are two main reasons for this problem:
First, the stamping formability of the aluminum alloy sheet with the same plastic hardening index n value is much lower than that of the cold-rolled steel sheet. The thickness of the aluminum itself is lower than the anisotropy index, the deep drawability is large, the elongation after partial fracture is low, the forming window is narrow, and the forming capacity is only 1/3 of that of the steel.
Second, aluminum has the characteristics of timeliness. As the heat treatment time increases, the strength, hardness, plasticity and toughness of aluminum itself decrease. Generally speaking, it takes 6 months to produce aluminum coils after heat treatment. In the 6-month production window, the mechanical properties of different batches of aluminum before production vary greatly due to aging, and the difference between mold margin and material properties Poor matching, necking and splitting occur from time to time.
1. Plate aging control
Aluminum sheet has aging properties, the strength increases with time, the hardness increases, and the plasticity decreases. Before stamping production, due to the different conditions such as the manufacturing process of the plate, the factory state after heat treatment, transportation, and temperature, the mechanical properties of the aluminum plate material before stamping production are quite different, which has a great impact on the production adjustment of the mold, and also leads to frequent production in continuous production. There are problems such as necking and pulling cracks. In order to solve this problem, we can first accumulate the range of mechanical properties for stable production of the mold, and then use the aging characteristics of aluminum to master the timeliness law, and stop using the aluminum with a low yield, so that it is naturally aged, and the yield strength is increased to After the expected range can be produced.
2. Early warning and intermittent supply of aluminum plate mechanical properties.
Renovate the board material card, and print all the board information on the material card, which is convenient for problems in the production process, and can quickly compare and analyze the performance of the material. In addition, the index data of performance problems in production is also summarized and summarized, and the performance early warning range of each aluminum alloy stamping part is formed, and the blue card material is used beyond the time range, which plays a role in early warning of defects.
3. Use digital methods such as Autoform and ATos to help optimize the pulling and cracking of the neck region.
The die set position is prone to necking, especially when the theoretical necking maximum point reported in the drawing simulation or exceeds the safety margin line (FLC), which can be optimized in digital software and equipment.
4. Intelligent grid monitoring system.
According to the experience, the position where the aluminum parts are prone to necking and fracture is summarized, and the mold margin monitoring is carried out on these parts. The main application is the grid strain analysis device (4×5 million pixel three-dimensional stereo camera), the hand-held camera shoots, and the specific situation of the grid strain in the monitoring area can be obtained. It takes about 1 hour from the shooting to the end of the computer operation. The advantage is that it is easy to operate , Fast and easy to calibrate. After the analysis report is output, it will prompt which location is safe and which location is risky. For risk points, mold maintenance personnel evaluate further optimization.
5. Develop equipment with special functions.
In the current stamping parts production equipment, the drawing lower air cushion can realize the function of segmental pressure. The cover plate is set with a small pressure in the early stage of forming, and then the air cushion pressure is set under the segment. The segmental pressure setting can effectively solve the cracking problem of deep-drawn aluminum alloy stampings.
The above is the relevant content of automobile aluminum alloy stamping parts processing. Any machining parts need different machining plans according to their materials and characteristics, and solve problems in a timely manner during the machining process. I hope the above will be helpful to readers.
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The cause of the injury
1. Between the workpiece and the mold
Adding a film such as PVC between the mold and the molding material can sometimes solve the problem of workpiece strain. For the production line, the film can be continuously provided by the mechanism. For the stamping equipment of periodic production, each workpiece needs to add a layer of film, which affects the production efficiency. This method is generally expensive and also produces a large amount of waste. For small batches of large workpieces Production is desirable.
2. Raw materials for forming workpieces
By surface treatment of the raw material, such as phosphating, spraying or other surface treatment, a non-metallic mold layer is formed on the surface of the material to be formed, which can greatly reduce or eliminate the strain of the workpiece. This method is often more expensive. high, and requires the addition of additional production equipment and increased production processes.
3. Mould
By changing the convex and concave ink materials of the mold or surface treatment of the convex and concave molds, the secondary properties of the contact between the finished material and the convex and concave molds are changed.
1. There are many ways to solve the problem of surface strain of workpiece and mold convex and concave mold. For different situations, the application method needs to be selected according to the size of the workpiece and the load, the production batch, the type of processing material, etc.
2. Using cemented carbide as the mold material, the chemical vapor phase of the convex and concave surface of the mold is deposited. TD is usually a cladding treatment. TD coating treatment is cost-effective.
Well, the above is what is the solution to the cause of the stretching die strain? I hope the above content can help readers.
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What affects the stability of stamping? First of all, we need to know that this stability can be divided into process stability and production stability. The former guarantees the quality of stamping products, and the latter guarantees the production capacity of stamping manufacturers. It can be seen that both are very important. The factors affecting stability are summarized as follows.1. The performance of stamping materials, the fluctuation of thickness, the variation range of materials and other factors have a certain impact on the quality of metal stamping parts and the stability of stamping dies;
2. The selection of stamping die materials and the strength design of die structures are directly related to the stability of metal stamping parts;
3. The resistance of draw bead and the variation range of blank holder force play an important role in the quality stability of metal stamping parts during drawing.
4. The reasonable selection of lubricant will directly affect the stability of stamping and the service life of stamping die.
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multiple draws complex shapes From prototype through full production run, we offer a wide range of deep drawing capabilities to meet the most demanding specs: cylindrical cans up to 200mm in length multiple draws and complex shapes All tooling for single die station, progressive and transfer ...
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Metal stamping parts are very common in daily life, so the metal stamping processing industry has been widely used. Currently, there are more than ten hardware products and hundreds of products on the metal market. Mainly include: locks, tensioning, door and window hardware, home decoration hardware, HVAC hardware, architectural decoration hardware, tools, bathroom hardware, kitchen hardware, etc. But in the processing of metal stamping parts, some problems will inevitably be encountered, how to deal with and deal with? The following editors of Zhejiang Baifudu Electromechanical will take you to understand the processing characteristics of metal stamping parts and the simple processing of stamping mold samples!
Metal stamping parts rely on presses and dies to apply external forces to plates, steel bars, pipes and profiles to plastically deform or separate, so as to obtain the forming and processing methods of workpieces of desired shape and size. In the stamping process, if the quality of the section and the dimensional accuracy of the workpiece are high, it can be repaired or used directly after stamping. In the production process of precision stamping parts, in order to improve the stability of stamping parts, the number of processes must be increased.
Metal stamping products have a long manufacturing cycle, many processes, and many abnormal situations (involving rework, scrap, split, replenishment, replacement, buffer materials, etc.), and the production process requires tracking and cost analysis. In addition, during the production process, customers can insert orders in time according to market changes, which is unpredictable by hardware companies. Relying on manual management, of course, cannot meet the change requirements of customer orders. Only after the order is confirmed, can it be included in the management. Sometimes the order status changes, but there is no timely response, often in a hurry. This shows that how to start information construction has become the primary problem facing hardware enterprise decision makers.
As a highly isolated industry, metal stamping parts often encounter bottlenecks under traditional manual management in daily production. First of all, the market competition is fierce, and user needs are constantly changing. Many hardware companies mainly focus on small batches and medium batches, and the design and manufacturing process of products often change according to customer needs. Therefore, hardware companies need to develop a good production plan to improve the flexibility of production and enable it to adapt to the market. The author believes that the products of general hardware enterprises are produced according to orders (contracts), the product structure is complex, the parts are many, outsourced and self-made. In the production process, relying on traditional manual management to rationally optimize production, the workload of production management is very large. The information and data of the department cannot be shared in a unified standard and interface, and it is inevitable that the delivery time cannot be scientifically controlled, which affects the execution rate of the order.
Second, metal stamping parts manufacturers have many outsourcing factories, involving many outsourcing factories, using traditional manual management methods, how to track and control the product quality, price, reputation of the metal stamping factory, and how the purchasing department controls the advance quantity, Ensuring that production does not go wrong, does not cause inventory backlog, and ensures a more reasonable level of capital occupation is a headache for hardware companies.
In many cases, the number of operations of a bent part is mainly determined by the complexity of its structural shape, which is determined by the number of bending angles. If the bending radius of the curved part is smaller than the allowable value, an additional forming process is required. Similarly, the number of processes and material properties of the drawn part, the drawing height, the number of drawing steps, the drawing diameter, the material thickness and other conditions are also affected and need to be determined by drawing process calculations. If the corner radius of the drawn part is small, or there is a certain requirement for dimensional accuracy, another forming process needs to be added after drawing. According to this model, the number of processes to determine stamping parts should also meet the conditions of the company’s existing mold capacity and stamping equipment. The molding ability should ensure mold processing, and the requirements for assembly accuracy should be improved accordingly, otherwise the number of processes can only be increased. For simple blanking parts, single-pass stamping dies are used; on the contrary, due to the limitation of die structure or strength, the inner and outer contours of complex stamping dies should be divided into multiple parts, requiring multiple stamping processes.
Recently, after receiving quotations for metal stamping products, many customers suggest to make some simple stamping dies to make some samples for testing. For these customers, we recommend customers not to make simple molds from the beginning. Especially for the following reasons:
1. Stamping parts that basically meet the requirements of the drawings cannot be produced.
The customer wants to use a simple mold as a sample, but has not confirmed the product in the early stage, and wants to spend less mold cost to test the sample. However, dimensional accuracy cannot be guaranteed for products manufactured by simple molds, even if the customer cannot be sure of the dimensional failure caused by the product.
2. A simple die cannot guarantee the uniformity of stamping parts.
A simple die cannot guarantee that each die is the same, because a simple die often does not have accessories such as positioning and guide posts, and there will be different offsets for each punch, which leads customers to inspect the stamping parts. , no satisfactory results can be obtained.
3. Failure to mass-produce simple stamping dies will result in waste.
The simple-packed punching meme has a simple structure and low precision, and can only be mass-produced after the customer confirms the sample. This will cause a lot of waste.
In fact, if the customer does not confirm the stamping product in the later stage, there is basically no need to open a simple die for sample testing, and other processing techniques can be considered to achieve it. Most steels are stamped, and punching can be made by other methods with ribs, ribs, undulations, or flanging to increase stiffness.
The above is the relevant content of metal stamping parts processing. In short, processing products through stamping process has become an important means and development direction of modern industrial production. However, the disadvantages of stamping parts are high mold requirements, complex manufacturing, long cycle and high manufacturing cost, which limit small batch production. Therefore, most stamping parts are mass-produced, which also reflects the importance of molds. I hope it helps readers.
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Dimensional tolerances of formed stampings: The formed stampings are divided into 10 precision grades, represented by FT1 to ft10, where ft represents the dimensional tolerance of the formed stampings, and the Arabic numerals indicate the tolerance level. Accuracy class reduced from FT1 to FT10.
The limit deviation of stamping parts: the stamping deviation of the hole size is 0, the upper deviation is the lower deviation plus the dimensional tolerance; the upper deviation of the shaft size is the basic deviation, the value is 0, and the lower deviation is the upper deviation minus the dimensional tolerance. The upper and lower deviations of hole center distance, hole edge distance, bend, stretch length and height are half the dimensional tolerance.
Tolerance is the range of dimensional variation. The lower the value, the lower the precision and the less difficult the processing; the lower the value, the higher the precision and the more difficult the processing. So what are the important considerations in production:
1. Bending angle: the angular size of the stamping part formed by bending.
2. Blanking angle: the angle dimension formed by blanking on the plane of the flat or forming part.
3. Blanking fillet radius: the linear dimension of the fillet radius of the stamping part, the parts processed by the separation process such as stamping and blanking.
4. Forming size: the angular size formed by the bending linear dimension of the stamping part processed by stretching and other processes.
5. Blanking size: the linear size of stamping parts, used for stamping, blanking and other separation processes.
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1. The process of stamping and drawing die
Punching die is a method of casting liquid die forging, a process completed on a special die-casting die forging machine. The basic process is: the molten metal is first cast into the mold cavity at a low speed or high speed, and the mold has a movable cavity surface. With the cooling process of the metal liquid, pressure forging not only eliminates the shrinkage defect of the blank, but also makes the internal structure of the blank reach forging. Broken grains.
1. Thermal fatigue crack damage failure
During die-casting production, the mold is repeatedly subjected to the action of cold and heat, the forming surface and its interior will be deformed, and they will be pulled together to generate repeated thermal stress, which will cause damage to the structure and loss of toughness, which will lead to the occurrence of micro-cracks and continue to expand. , once the crack expands, the molten metal is continuously squeezed in, coupled with repeated mechanical stress, the crack accelerates the expansion rate. Therefore, the mold must be fully preheated at the beginning of die casting. In addition, during the production process of die casting, the mold must be kept in a moderate working temperature range to prevent early cracking failure. At the same time, it should be ensured that there are no problems with internal factors before the mold is put into production and during production. Because in actual production, most mold failures are failures caused by thermal fatigue cracks.
2. Fragmentation failure
Under the action of pressure, the mold will crack at the weak place, especially if the scribe marks or electrical machining marks on the molding surface of the mold are not polished, or the clear corners of the molding will appear micro cracks first. When there is a brittle phase or coarse grains in the boundary, it is easy to fracture. However, the cracks expand rapidly during brittle fracture, which is a very dangerous factor for the chipping failure of the mold. For this reason, on the one hand, all scratches and electrical machining marks on the mold surface must be polished, even if it is in the gating system part, it must be polished. In addition, the mold materials used are required to have high strength, good plasticity, good impact toughness and fracture toughness.
3. Dissolution failure
Commonly used die-casting alloys include zinc alloy, aluminum alloy, magnesium alloy and copper alloy, as well as pure aluminum die-casting. Zn, Al, and Mg are more active metal elements, and they have a good affinity with mold materials. When the hardness of the mold is higher, the corrosion resistance is better, and if there are soft spots on the molding surface, the corrosion resistance is unfavorable.
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1. Can use CAD mold processing method
When processing molds, a common method is the mold CAD method. When processing molds, this method generally adopts some ready-made mold standards to directly process molds. Because there are many products in design, the appearance is very similar, so in processing When making molds, for these products with small differences in appearance, some existing mold standards can be directly selected for processing and manufacturing, so that the molds can be manufactured faster. This manufacturing method is suitable for many mold processing and manufacturing, and some integrated technologies can be used when manufacturing molds.
Second, you can choose the die CAD mold processing method
When manufacturing molds by this method, it is somewhat similar to the first method, but it is improved on the basis of the previous method. When using this method to process and manufacture molds, some blanks are used, and the blanks are further optimized, so that the utilization rate of the manufactured molds is higher. When using this method to manufacture molds, due to the different requirements of each part, the methods used are also different in the stamping process. Using this method can greatly improve the utilization rate of blank materials.
With the continuous development of science and technology, computers play an increasingly important role in people’s lives. When people process and make molds, they can use the computer to lay out the layout and lay out several different styles through the computer. When using a computer for nesting, people can use two different nesting methods: semi-automatic and fully automatic. These two different nesting methods use different algorithms and characteristics. The entire production process can be completed more efficiently during processing.
When manufacturing the mold, people can also use some mathematical models to describe the mold, and then use the stamping process to process and manufacture the mold. When this method is used, the precision of the manufactured mold can be higher. , the structure of each part is more perfect, and the strength of the mold can be relatively strong. By stamping the mold in an all-round way, the manufactured mold can more meet the needs of people.
There are many different mold processing methods, and people can choose different methods according to their needs for molds.
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With the improvement of science and technology, people have higher and higher requirements for the precision of products. The stamping industry is no exception. While the demand of customers for precision stamping parts is growing, the precision requirements for products are also increasing. In the production process, the production of precision stamping parts should not only consider the shape and size of the product, but also consider the impact of stamping dies, punches and other matters. In order to ensure the production of qualified precision stamping parts, Balford Precision has summarized the following points needing attention after years of production experience and shared them with everyone:
In addition to the same preventive measures as conventional stamping parts, the main purpose of ensuring the product quality of precision stamping parts is to pay attention to the maintenance and care of the punch and stamping die. Only under the condition of ensuring the accuracy of the punch and die can the stamping factory produce qualified precision stamping parts.
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Stamping (also known as pressing) is the process of placing flat sheet metal in either blank or coil form into a stamping press where a tool and die surface forms the metal into a net shape. Stamping includes a variety of sheet-metal forming manufacturing processes, such as punching using a machine press or stamping press, blanking, embossing, bending, flanging, and coining. This could be a single stage operation where every stroke of the press produces the desired form on the sheet metal part, or could occur through a series of stages. The process is usually carried out on sheet metal, but can also be used on other materials, such as polystyrene. Progressive dies are commonly fed from a coil of steel, coil reel for unwinding of coil to a straightener to level the coil and then into a feeder which advances the material into the press and die at a predetermined feed length. Depending on part complexity, the number of stations in the die can be determined.
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When considering deep drawing to meet your manufacturing needs, you should pay attention to the following points:
Reduce material waste: compared to other metal forming processes, deep drawing uses more base materials, significantly reducing material waste.
Measurement is critical: it is not only important to ensure accurate mold dimensions, but also important to consider material thickness and required measurement values. Incorrect measurement will lead to thin walls and inaccurate dimensions.
Draft and Taper: Due to the basic manufacturing process of deep drawing, some drafts and tapers at the top of the part are unavoidable. This should be considered at the initial design stage.
Different material thicknesses: Deep drawing parts usually have different thicknesses, with thinner walls and thicker bases. This can be mitigated by tools after the wire drawing process is completed.
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Minimize guide and weld issues with deep drawn metallic enclosures. When engineering depends with a situation to perform reliably, even within the most demanding environments, it is really the perfect time to
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Hardness is usually the basis for measuring the heat treatment quality and performance of molds, and hardness is an important performance indicator of mold materials and finished molds. The stress state of the hot mold during the working process is very complex. For example, the hot mold is generally subjected to alternating stress in an alternating temperature field. Therefore, the mold should prevent the mold from becoming soft or plastic, and maintain its shape and size in a long-term working environment. Precision remains unchanged. Usually, the hardness of the finished product and the cold mold are usually 59-60HRC, and the hot work mold is often used around 48HRC.
Wear resistance is an important performance indicator of the finished mold. During the molding process, the metal moves relative to the surface of the mold cavity, causing the cavity surface to wear, and the mold size, shape, precision and surface roughness to change and fail. Wear resistance mainly depends on the heat treatment of the mold, especially the surface heat treatment. The main basis for evaluating the wear resistance of the mold is the hardness.
The test hardness test is mainly aimed at three situations, namely the hardness test of the die steel material, the heat treatment hardness test of the semi-finished mold, and the surface hardness test after the heat treatment of the mold surface.
Steel mold materials are mainly forged steel plates, steel blocks or steel bars, which are generally supplied in an annealed state. Some plastic steel molds also provide pre-hardening (quenching and tempering treatment), and users can directly process them into molds without subsequent heat treatment. According to different steel types, die steel can be divided into carbon tool steel, alloy tool steel and high-speed tool steel. The Chinese standard specifies the factory hardness requirements of various die steels, and tests the annealing hardness and quenching hardness of the steel. Mattel Leeb hardness tester is widely used, with fast detection speed and simple operation, and the detection value can be automatically converted into Brinell hardness value, so it has been widely used.
The die steel material that has been machined must be quenched and tempered, and can be made into a finished die after fine grinding and polishing. It is more important to test the hardness of the quenched and tempered mold, because the hardness of the material is a very important quality index at this time, which determines the service life of the finished mold to a large extent. Quenched and tempered mold materials require a Rockwell hardness tester to measure HRC Rockwell hardness. Molded products are required to have the best comprehensive mechanical properties, not only sufficient hardness, but also certain toughness. Hardness and toughness are a pair of contradictions. In order to achieve reasonable toughness and make the mold have higher hardness, the most Optimal hardness values will be limited to a fairly small range, typically 2-4 HRC units.
There are great difficulties in hardness testing of finished and semi-finished products. There is no more ideal solution. Only a small number of molds that are small in size and weight can be moved to a benchtop Rockwell hardness tester for testing. For finished products, the Leeb hardness tester is a solution to hardness testing semi-finished products and Leeb hardness before converting to HRC on Rockwell hardness. At present, the commonly used method in the mold industry is to use a Leeb hardness tester to measure hardness, and the Mattel Leeb hardness tester is the most widely used in the mold industry.
As mentioned above, the reasonable hardness range of finished and semi-finished molds is narrow, and the Leeb hardness tester cannot meet this precision requirement. But this is also the current status of the mold industry, and there is no better solution. For surface carburizing, nitriding or laser quenching treatment, the surface hardness of the mold with surface hardening treatment should be tested. When the thickness of the infiltrated layer exceeds 0.8mm, the hardness of HRC can be directly measured by a Rockwell hardness tester. When the thickness of the carburized layer is 0.6-0.8mm, the A scale of the Rockwell hardness tester can be used. The test pressure A=60kg (the C-level test force value is 150kg), which can press a shallow indentation on the surface of the mold, so that the hardened layer will not be penetrated, and the hardness test is relatively accurate. HRA hardness measurements are easily converted to HRC hardness values by looking up the table. If the thickness exceeds 0.1mm, a surface Rockwell hardness tester can be used for thinner carburized or nitrided layers. Ground Rockwell hardness tester is only 15kg, 30kg or 45kg. For example, when a surface Rockwell hardness is 60HRC, the surface Rockwell hardness value is 90.6HR15N, and the indentation depth is equal to (100-90.6)X0.001mm=0.009mm, in this case, it is almost difficult to distinguish. Therefore, the surface Rockwell hardness tester can also test the finished product, and the obtained hardness value can also be converted into HRC hardness value.
For die steel, hardness is the most important property. To account for other properties, such as toughness, its optimum hardness range is narrow. Therefore, how to use the Mattel portable hardness tester to test the hardness of the mold quickly and accurately is of great significance to the mold manufacturing and use units. It can improve the quality of mold products, improve the mold manufacturing process, and prolong the service life of the mold.
In fact, the hardness of the mold processing material is not bad, only the wrong material is used in a specific area. Therefore, designers must fully understand the properties of various materials, and carefully test the materials, and carefully test the materials to study the influence of various factors on the performance of molded products. Hopefully the above will be useful to the reader.
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1. Reasons for unqualified products of metal stamping parts
1. The product is unqualified due to the springback of the material. At this time, we can reduce the springback of the stamping parts through the following methods, use the stamping material with stable mechanical properties, increase the annealing process, and use the correction bending. The material should be de-fired before bending, and the cooled material should be softened before bending; if it is difficult to eliminate the deformation during the stamping process, the slope of the model should be adjusted at this time.
2. If there is a problem with the positioning of the strip due to the deformation and wear of the positioner, a new positioner must be replaced.
3. When adjusting the press, if the low position of the slider is not adjusted well, the bending parts are not qualified.
4. The pressing equipment of the mold does not have the function of pressing the material. It must be repaired or replaced with a new pressing spring or the pressing force must be adjusted.
5. After a long time of use, some parts of the mold are loose, which causes the position of the abrasive tool to change.
6. It may also be caused by the operator not using the mold as required.
The above is why there are unqualified metal stamping parts. I hope the above content can help readers.
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