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Showing content with the highest reputation since 10/27/2020 in all areas

  1. In reply to this post, I created a representation about types of manufacturing processes, process selection and about the latest technologies and processes of additive manufacturing, a very comprehensive and up to date 1-page graphical representation attached on drive with the QR code. Hope you will learn something..
    10 points
  2. Attn Conference extended till 14th Oct 21 Guidelines & Rules for open ended conference Write one statement or few lines related to (any) Manufacturing & Production technology which may include process introduction application Cost benefit analysis pros and cons Diagrammatic representation latest trends And.....no limits Collective (joint) effort from all participants should be such that, none of the topic remain untouched. Your creative and innovative approach will lead to an interesting presentation in just few sentences. Do not repeat which has been already posted before your post Preference to English language only Do not post twice... If needed edit your already written post. 3 Participants each from Lucky draws will be chosen and awarded Amazon gift card $10 (750 INR), but they must have 5 likes to their posts Look forward for your active participation... and please do encourage all your mechanical engineer friends to participate Please appreciate the post of other members by liking the same. I am writing the first statement to give it a start Gears can be manufactured by a variety of processes, including casting, forging, extrusion, powder metallurgy, and blanking. Next member can chip in to extend his talk on the gear manufacturing or can write on other manufacturing process.
    7 points
  3. Product Development of production machinery is expensive and time consuming, building a machine and throwing it into production with minimal testing can be risky and rewarding at the same time. Once you have started to produce a consumer product and a customer demand, it can be detrimental to the business when your proprietary machinery breaks down at regular intervals or for long periods of time, causing unpredictability in your supply chain. It is good if possible to have multiple machines that produce the same product so that downtime is available for maintenance, repair, and upgrade without compromising the supply of product to your customer. Many times in my career, I have been asked to build a machine or device to accomplish a specific purpose. Before I start designing, I do a thorough investigation to see if there are any machines that accomplish the same or similar purpose. On many occasions I have made some minor modifications to an existing machine that was readily available to accomplish the objective of my project. By doing this I can harness the time that the manufacturer has invested in the development of that machine and avoid costly down time. In the recent past, I was tasked to design and produce some custom conveyors that need to be a size that was a few inches wider than anything available in the time frame that they were needed. I gave it my best effort and we produced hundreds of thousands of dollars worth of conveyors and put them into production. I based my design off of a conveyor that we had purchased and made enough changes in the construction methods to avoid any patent infringement. I missed one key element, the leg weldments of the existing conveyor is a substantial weldment that provides stability and keeps the frame of the conveyor square. I designed the legs for my conveyor out of bent sheet metal and minimal welding that bolt together to allow them to be disassembled for shipping. Unfortunately they do not have structural ability to keep the roller support frame of the conveyor square. We discovered that if the line of conveyors got bumped by a forklift, it was possible for the frames of the conveyors to be out of square enough to cause resistance in the rollers and cause a high load fault in the electrical drive. I was aware of the issue and designed a brace to add to the roller support frame, but was never given the time or the resources to add it to the many conveyors that had already been placed in production. I have since been informed that they have discontinued use of these conveyors and have replaced them. Lessons learned: Build a prototype and thoroughly test it before rushing into production. Shortcuts often cause more problems in the long run. The devil is in the details, some of the smallest issues that seem inconsequential can kill the whole project. The process of Product Development is expensive and takes time, just because you have the capability to build something doesn't mean that you should.
    5 points
  4. MANUFACTURE OF PLASTIC COMPONENTS FOR AUTOMOBILE BODIES Amidst increasing fuel prices and its impact on the environment, electric vehicles are finding a permanent spot in every garages these days. While advances are being made every day in terms of battery and motor performances in these vehicles, as a mechanical design engineer, one can start looking for suitable materials for the manufacture of vehicle bodies. While traditional steel and aluminium structures are being replaced by plastics, the manufacturing process for the same is a topic worth mentioning. Let us take a look at one of the most widely used manufacturing process for a typical thermoplastic component: Injection Moulding. INJECTION MOULDING Injection moulding is the most widely used process for the high-volume production of relatively complex thermoplastic parts. In this process, plastic material is melted and injected into a mould to create a part. Once this part cools, the mould opens, and the part drops out. Granules of raw material are fed by gravity from a hopper into a cavity that lies ahead of a moving plunger. As the plunger advances, the material is forced through a preheating chamber and on through a torpedo section, where it is mixed, melted, and superheated. The superheated material is then driven through a nozzle that seats against a mould. Sprues and runners then channel the molten material into one or more closed-die cavities. Because the dies remain cool, the plastic solidifies almost as soon as the mould is filled. The mould halves must clamp tightly together during moulding and then be easily separated for part ejection. Injection moulding is an established process for many exterior automotive components, including fenders, grilles, bumpers, door panels, floor rails, light housings, etc. Other applications include instrumentation components, interior surfaces, dashboard faceplates, door handles, glove compartments, air vents etc. NOTE: Hand drawing sketch of the injection moulding process has been attached along with this write up.
    5 points
  5. Manufacturing method for Composites - Pultrusion The process of Pultrusion is utilised for the manufacture of the components which have a constant cross-sectional shape ( beams, rods, tubes etc.),and continuous lengths. In Pultrusion process, thermosetting resins are first used to impregnate continuous fiberrovings or tows; then they are pulled through a steel die which then provides the required shape to the stock and also sets the ratio resin/fibre. After this, the stock is then passed through a curing die which is precision machined so that it can give the final shape to it. This die is also heated to start curing of the resin matrix. Then the stock is drawn through the dies with the help of a pulling device. This step also determines the production speed as well. Glass, Aramid fibres and carbon are primary reinforcements materials, usually added in concentrations of approximately ranging from 40 and 70 vol%. The matrix materials commonly used in this process are polyesters, vinyl esters, and epoxy resins. Diagram of the pultrusion process. Continuous roll of reinforced fibers/woven fiber mat Tension roller Resin impregnator Resin soaked fiber Die and heat source Pull mechanism Finished hardened fiber reinforced polymer
    4 points
  6. The best way to redesign and understand any thing is reverse engineering. The best possible practise can be done through 3 D scanner and 3D printer. This is how you can actually find what is the fault in any model/predesigned structure.
    4 points
  7. I am involved in the mining industry over 38 years and in my travels world wide and not mentioning any specific OEM the reliability, durability with high production and low maintenance costs is the highest priority for all of them. Huge costs is used every year by these OEM`s to improve on their equipment and machinery using IoT and even go autonomous. Everyone is actually missing 1 important point " The Human Factor" , 75% of machinery breakdowns is directly linked to human error causing self inflicted breakdowns. Some of the machines have very sensitive and state of the art hydraulic systems and control valves with tolerance's less than 4 microns. All this help nothing if the system is not maintained properly and parts / components is not replaced in a 100% clean manner and correct tightening torques ect. When talking about lubricants in use there can be a million of books written about it but the basics stays the basics. Keep hydraulic oil clean, below 80 degrees Celsius, correct viscosity, correct grade and regular sampling tests.
    3 points
  8. Laser Beam Welding Laser beam welding (LBW) is a welding technique used to join pieces of metal or thermoplastics using a laser. The beam provides a concentrated heat source, allowing for narrow, deep welds and high welding rates. The depth of penetration is proportional to the amount of power supplied but is also dependent on the location of the focal point. Audi Q5 aluminum tailgate with weld [Pic Source] Laser Welding – Key Benefits • Can be easily automated using a CAD/CAM setup. • No electrode is used in the process and no form of tool wear occurs. • High level of accuracy and ultimate precision. • High-quality welds are obtained through the use of a laser, capable of creating complicated joints. • The beam provides a concentrated heat source, allowing for narrow, deep welds and high welding rates. • Weight saving potential due to reduced flange sizes. Weight saving can be achieved by the modification of the flanges. While a spot weld connection usually requires a flange width of about 16 mm for all bonded parts to guarantee accessibility for the spot welding gun, a laser beam weld necessitates only circa 8 mm of flange width, since the laser gun itself does not need to physically access the flange. Flange width comparison between resistance spot weld and laser beam weld flange
    3 points
  9. Look at plain of base as flatness into infinite space. With index finger parallel to base x y with z depth. What are mathematical formula and forms can you "see" in graphic detail and what occurs if plain is tilted on 4 nonstandard axial rotation?
    3 points
  10. DrD

    Planetary Gear Challenge, #55

    Mechanics Corner A Journal of Applied Mechanics and Mathematics by DrD, #55 Planetary Gear Challenge Introduction Back in the mid-1990s, I worked as the "in-house consultant" for a small aerospace manufacturing firm in the Chicago suburbs (500 employees). The general rule was simply that any engineer in the company could bring me any problem, and I would try to give them a solution. It was one of the happiest jobs I've ever had because I was constantly being given new problems to work on. Some of the problems were simple, the sort that could be solved in 20 minutes with pencil and paper. Others took many days and lots of computer work, but I had a free hand and I really enjoyed it. For the figure and the remainder of this challenge, please see the PDF file. I am unable to save the figure in a format that will allow me to upload it here. -- DrD Planetary Gear Challenge.pdf
    2 points
  11. The Fourth Industrial Revolution (4IR or Industry 4.0) is the ongoing automation of traditional manufacturing and industrial practices, using modern smart technology. Large-scale machine-to-machine communication (M2M) and the internet of things (IoT) are integrated for increased automation, improved communication and self-monitoring, and production of smart machines that can analyze and diagnose issues without the need for human intervention. (e.g. 3 D printing deploying basic mechanical processes like metal powder spray done using smart automation.) Best of Mechanical to collaborate with latest of digital to produce Mecha-digital outcomes.
    2 points
  12. Smart tools are required for smart innovation, and use nano componen matereals for better production & better quality
    2 points
  13. There are dependencies at every level of manufacturing, consistent reliable construction materials being one of the most critical to positive results. There has been a disturbing trend of sub-standard steel deliveries world wide, vendors cutting corners on specified deliveries. In at least two cases structural components in completed buildings have been found sub-standard After the major structure was up, and steel delivered for component manufacturing is widely unreliable and out of standard. It is now necessary to keep an inspection crew testing deliveries, and in the case of large foreign shipments an inspection crew needs travel to inspect the steel Before shipment from marshaling yards.
    2 points
  14. First day at work in a new Company and my director says that our main customer requires us to implement a Production Part Approval Process (PPAP) for their particular product stream. My director says he doesn't particularly want, or have the time to be involved and can I just get on with the implementation? This happened to me and was as perfect a Company introduction process as it would be possible to have! Straight into meeting and discussions with relevant staff, introducing all the relevant quality and production control documentation, presenting the finished process to the customer and getting the initial sign off first time. After 40 years in manufacturing it's great to still be able to learn and make progress
    2 points
  15. As in forging there are two types o forging, hot forging and cold forging. The gear is manufactured by either way, each way has its pros and cons. I'll state about cold forging, it is a new method of gear manufacturing, not as new as state of the art but it is quite rarely used. by cold forging of gears there are various stresses generated as metal is not adequate to deformation. Thus it is point of advantage if you want to develop compressive stresses as to improve the fatigue life.
    2 points
  16. Crystallisation is the transformation of a solution into solid which in turn leads to the nucleation of supersaturated solution. During crystallization well-defined and uniform particle structures are formed.
    2 points
  17. Railways wagon manufacturing requires a high quality steel depending upon application such as for preventing rust iron cannot be used, so stainless steel is used. More research need to be done for rust proof material ,durable and cheaper.
    2 points
  18. Heat treatment is the process which improves physical (mechanical) Properties of the material.depending on the application different heat treatment processes are used. This process increases the product life which directly decreases maintenance cost and failure of the product
    2 points
  19. Hot Rolling It is a production process for getting finished product close to tolerance limit. It involves pre heating, rolling, quenching & tempering. Advantage 1. good surface finished 2. high production rate 3. close to tolerance limit 4. high strength
    2 points
  20. Modern CAD CAM practices have enhanced our engineering capabilities as compared to earlier methods such as using mock ups, by being able to achieve high standards of work, quality of work and cutting the cost of production in the long run. Quick question though, does reverse engineering protect intellectual property rights?
    2 points
  21. Screw compressor is one of the most used compressor in industrial air production. Most important and most neglected part of the screw compressor is air filter. For the other spare parts like oil filter, oil separator, cooling oil we remain alert, but normally we do not care about air filter mostly. Just clean it mostly..... Damaged Air filter cause maximum problem of the compressor. As it can not be cleaned so good. So timely replacement of the air filter is the best practice to run the screw compressor in good condition.
    2 points
  22. We have found casting some of our parts makes them able to handle much higher torque levels. We are always keen to use the best possible components for the Thompson Couplings to enable us to offer a reliable, maintenance free option. Having the end users in mind and thinking of their- experience and needs for their production or plant at the heart of decisions creates a much more reliable, long lasting quality product. Focus should always be the customers needs and quality products. We have also used 3D printing to create samples.
    2 points
  23. Interchangeability of jigs and fixtures is the essential requirement for shop floor since it helps to save set up time and cost of procurement of new jigs.
    2 points
  24. One innovative aspect relates to the possibility of using solid state laser cooling to accelerate by leaps and bounds what seems to be the main bottleneck in metallurgical (or any material ) formation / fabrication (starting from extraction) processes, i.e the thermodynamic aspects of heating / cooling (which can now be carried out using precisely controlled laser power pulses / waves
    2 points
  25. Time is a measurement of motion in space and numbers are based only from geometry use that information WD40 and Duct tape and you can engineer anything even more universes...
    2 points
  26. admin

    Chain-Sprocket-System

    From the album: Engineering Images

    Chain & Sprocket System:- A sprocket is basically a toothed wheel which fits onto the shaft. It is prevent from rotation on to the shaft by the keyways in the shaft and sprocket. A chain is used to connect two sprocket each other with them, one sprocket is called the driver sprocket and the other one is called driven sprocket. Transmission of force and motion via over the chain to the one sprocket to another one, so therefore from one shaft to another shaft. Transmission of force and motion via chain to one sprocket to another one this process is called the power transmission chains.
    2 points
  27. Version 1.1.0

    44,475 downloads

    A COMPLETE INSTRUCTOR AND STUDENT SUPPLEMENT PACKAGE - Continued These ppts are set of instructor and student supplements. . A FOCUS ON DIAGNOSIS AND PROBLEM SOLVING The primary focus of these ppts is to satisfy the need for problem diagnosis. Time and again, the author has heard that technicians need more training in diagnostic procedures and skill development. To meet this need and to help illustrate how real problems are solved, diagnostic stories are included throughout. Each new topic covers the parts involved as well as their purpose, function, and operation, and how to test and diagnose each system.
    2 points
  28. Selection of material is an important aspect for manufacturing industries . The quality of product is highly depends upon its material properties. These properties are used to distinguish materials from each other. For Example: A harder material is used to make tools.A ductile material is used to draw wires. So the knowledge of mechanical properties of material is desirable for any mechanical student or for any person belongs to mechanical industries. This post brings top 18 mechanical properties. Mechanical properties of material: There are mainly two types of materials. First one is metal and other one is non metals. Metals are classified into two types : Ferrous metals and Non-ferrous metals. Ferrous metals mainly consist iron with comparatively small addition of other materials. It includes iron and its alloy such as cast iron, steel, HSS etc. Ferrous metals are widely used in mechanical industries for its various advantages. Nonferrous metals contain little or no iron. It includes aluminum, magnesium, copper, zinc etc. Most Mechanical properties are associated with metals. These are #1. Strength: The ability of material to withstand load without failure is known as strength. If a material can bear more load, it means it has more strength. Strength of any material mainly depends on type of loading and deformation before fracture. According to loading types, strength can be classified into three types. a. Tensile strength: b. Compressive strength: 3. Shear strength: According to the deformation before fracture, strength can be classified into three types. a. Elastic strength: b. Yield strength: c. Ultimate strength: #2. Homogeneity: If a material has same properties throughout its geometry, known as homogeneous material and the property is known as homogeneity. It is an ideal situation but practically no material is homogeneous. #3. Isotropy: A material which has same elastic properties along its all loading direction known as isotropic material. #4. Anisotropy: A material which exhibits different elastic properties in different loading direction known as an-isotropic material. #5. Elasticity: If a material regain its original dimension after removal of load, it is known as elastic material and the property by virtue of which it regains its original shape is known as elasticity. Every material possess some elasticity. It is measure as the ratio of stress to strain under elastic limit. #6. Plasticity: The ability of material to undergo some degree of permanent deformation without failure after removal of load is known as plasticity. This property is used for shaping material by metal working. It is mainly depends on temperature and elastic strength of material. #7. Ductility: Ductility is a property by virtue of which metal can be drawn into wires. It can also define as a property which permits permanent deformation before fracture under tensile loading. The amount of permanent deformation (measure in percentage elongation) decides either the material is ductile or not. Percentage elongation = (Final Gauge Length – Original Gauge Length )*100/ Original Gauge Length If the percentage elongation is greater than 5% in a gauge length 50 mm, the material is ductile and if it less than 5% it is not. #8. Brittleness: Brittleness is a property by virtue of which, a material will fail under loading without significant change in dimension. Glass and cast iron are well known brittle materials. #9. Stiffness: The ability of material to resist elastic deformation or deflection during loading, known as stiffness. A material which offers small change in dimension during loading is more stiffer. For example steel is stiffer than aluminum. #10. Hardness: The property of a material to resist penetration is known as hardness. It is an ability to resist scratching, abrasion or cutting. It is also define as an ability to resist fracture under point loading. #11. Toughness: Toughness is defined as an ability to withstand with plastic or elastic deformation without failure. It is defined as the amount of energy absorbed before actual fracture. #12. Malleability: A property by virtue of which a metal can flatten into thin sheets, known as malleability. It is also define as a property which permits plastic deformation under compression loading. #13. Machinability: A property by virtue of which a material can be cut easily. #14. Damping: The ability of metal to dissipate the energy of vibration or cyclic stress is called damping. Cast iron has good damping property, that’s why most of machines body made by cast iron. #15. Creep: The slow and progressive change in dimension of a material under influence of its safe working stress for long time is known as creep. Creep is mainly depend on time and temperature. The maximum amount of stress under which a material withstand during infinite time is known as creep strength. #16. Resilience: The amount of energy absorb under elastic limit during loading is called resilience. The maximum amount of the energy absorb under elastic limit is called proof resilience. #17. Fatigue Strength: The failure of a work piece under cyclic load or repeated load below its ultimate limit is known as fatigue. The maximum amount of cyclic load which a work piece can bear for infinite number of cycle is called fatigue strength. Fatigue strength is also depend on work piece shape, geometry, surface finish etc. #18. Embrittlement: The loss of ductility of a metal caused by physical or chemical changes, which make it brittle, is called embrittlement.
    2 points
  29. Mechanical Engineer - Repair and Maintenance - Production Technology Dep. - Mpande Limestone (Sinoma Cement)
    2 points
  30. Mechanical Inspector - MBEYA CEMENT COMPANY LIMITED In Maintenance Department and Preventive/Method Section.
    2 points
  31. Mobile Equipment Engineer - Mimosa Mining Company - provide maintenance service for all underground TMMs
    2 points
  32. Technical Advisor- Experimental Fluid Dynamics Engineer at Cummins Inc.
    2 points
  33. My position is Principal Engineer, Mechanical (Thermal Plant) and my role is to provide technical support on rotating equipment mechanical issues to our thermal power plants.
    2 points
  34. I took more math classes than the math majors--not a one wasted. I often call myself an applied mathematician. Math has enabled me to do all sorts of things besides mechanical engineering. I worked with several remediation teams when none of the geologists or geohydrologists or civil engineers could handle the mathematics. I solved several of the biggest pollution nightmares in North America, including the most expensive cleanup ever--on Western Cape Cod in the Kennedy's back yard. My particle tracker and 3D model builder software were the premier tools of choice for contractors working for the US Departments of Defense and Energy plus the Environmental Protection Agency for over a decade. I don't mean to be critical, but it has been my experience that engineers who don't have the "knack" (see Dilbert for details) and don't have a strong command of mathematics, end up in management. Of course, some people prefer management. I'd rather be drawn and quartered.
    2 points
  35. Friction Stir Welding Manufacturing companies dealing with high stress and pressure [aerospace], typically avoid welds, because of the weakness it creates in the metal and its limitations. But mastering friction stir welding could result to a much stronger bonds than traditional welds. As you can join large, thin sheets of metal [ex. Light-weight alloys], and shave off pounds of weight by avoiding the use of rivets, fasteners, and other support structures. Making the manufactured device /machine, lighter and stronger.
    1 point
  36. Check the club section https://mechanical-engg.com/clubs/28-fluid-mechanics/
    1 point
  37. After solving I got d=29.1 mm After solving d= 29.1 mm or d= 30 mm
    1 point
  38. Answer is, diameter (d)= 29mm.
    1 point
  39. Please reply Name Engineering college Location (City/ Country) Engineering Batch Engineering Company/ Dream company to work for Area of Interest Project undertaken Any other info you want to share
    1 point
  40. I am a mechanical engineer working as a Chief Engineer role in a Hotel & Hospitality Industry, Department of Engineering. USA Annapolis, Maryland. Thank you.
    1 point
  41. Engineering Manager, Manufacturing of Composite Rail Platforms
    1 point
  42. DrD

    Hemispherical dome

    It is far better for you to read the book. I have not done such problems since I taught a course where they were included in the Fall semester, 1969. My memory is a bit fuzzy, and I'd probably mislead you. DrD
    1 point
  43. The power delivered by each piston would be the equivalent of the individual rotation of the crank, and the amount of torque on the flywheel.
    1 point
  44. Not knowing the application and loads. The most likely screw sizes would be #10-32 UNJF-3A. This will require using MS21209F1-15L at minimum. If you using Boeing specs that would callout the holes to BACD2079N030B3R. If Airbus, I would have to look that up. Note: There would always be tensional loads. All Screws/Bolts are designed to have tensional loads. There are some that are shear loaded and those have a solid shank larger than the threads that require match reaming to shear load. The most common application for that method would be the seat tracks or structural framing.
    1 point
  45. pms engineers

    Bearings

    PMS Engineers is an established supplier of world class bearings and power transmission products. We are the first-choice channel partners for some of the world’s biggest bearing and lubricant manufacturers including Timken, NSK-RHP, NIKKI, Gamet Bearings and Motherson Sumitomo – Solid Carbide Cutting Tools. With a powerful distribution network and support team in place, we collaborate with clients round the clock to minimize downtime, reduce working costs and improve the overall quality of operations.
    1 point
  46. I used to teach a course at university on process optimization. There are several simple problems that can be solved using Excel. For example, it takes so long to produce X and a different time to produce Y and another time to switch over from one to the other. If you must produce a total of Z, what is the optimal approach? The Tom's cracker factory is less than a mile from my house. [Sadly, they have since closed )-;] They made cheese and also peanut butter crackers on the same machines and it takes a while to switch over. There is also a factory in town that makes plastic door mats and also special mats to use at the driving range to whack golf balls. That is also done on the same machine. Shutting the machine down and bringing it up again wastes $15,000; so the decision is not made lightly. I have attached a few spreadsheets, of course, one of them must be McDonalds Big Mac and fries! AutoAssembly.xls cabinets.xls carsales.xls mcdonalds.xls WhittWindowCo.xls
    1 point
  47. parsottam

    HAZOP & HAZIP

    HAZOP, which stands for hazard and operability study, is used to identify abnormalities in the working environment and pinpoint the root causes of the abnormalities. It deals with comprehensive and complex workplace operations, which, if malfunctions were to occur, could lead to significant injury or loss of life. HAZID stands for hazard identification. It is more of a general risk analysis tool designed to alert management to threats and hazards as early in the process as possible. The classification is made on the basis of probability and consequences. A HAZID study provides a qualitative analysis of a work site in order to determine its worker safety risk level. Both HAZID and HAZOP are risk analysis tools used in the workplace
    1 point
  48. Compression ratio is the ratio between the volume in the cylinder, when the piston is in bottom dead centre, and the volume, when the piston is in the top dead centre. So: CR=Vbdc/Vtdc Then you have the swept area, the engine displacement, which is: SA=Vbdc-Vtdc Volumetric efficiency is the amount of air/fuel mixture that gets to the piston compared to the swept area - if the same volume of the mixture goes in, you have a 100 % efficiency. Usually it's a bit less, since you are creating a small vacuum when the piston is going down (with naturally aspirated engines) and that doesn't even out with the surrounding air pressure before the intake valve closes, but with proper tuning (think racing engines, F1 for example) it is possible to get over 100 % volumetric efficiency in a naturally aspirated engine.
    1 point
  49. i want to convert my two stroke petrol engine into an engine which will run on LPG .i want to know ,s it possible and if yes .please guide me. i will be very much thankful to you all
    1 point





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