Journal of the Brazilian Society of Mechanical Sciences and Engineering (2020) 42:349

https://doi.org/10.1007/s40430-020-02436-w

TECHNICAL PAPER

Experimental and finite element investigation of high‑speed bone

drilling: evaluation of force and temperature
Mohsen Sarparast1 · Majid Ghoreishi1 · Tohid Jahangirpoor1 · Vahid Tahmasbi2

Received: 14 November 2019 / Accepted: 25 May 2020

© The Brazilian Society of Mechanical Sciences and Engineering 2020

Abstract
Currently, in the world of orthopedic surgeries, bone drilling is prevalent to hold broken bones and for bone implantation.
Increase of bone temperature higher than 47 °C leads to a notorious phenomenon named thermal necrosis, which eventuates
in cellular death of the bone tissue. Consequently, there is a chance for a loose implant after the operation. In this paper, for
the first time, a 3D thermo-mechanical finite element (FE) model of a high-speed bone drilling process was introduced to
study process force and temperature. Then comparing experimental results with numerical ones, the influence of the rotational
speed and feed rate on both process force and the temperature was investigated. This study revealed that in high-speed drilling
of the bone with a raise in rotational speed, due to different chip deformation and reduced chip thickness, both process force
and temperature reduce remarkably. According to experimental and numerical findings, the optimum bone drilling setting
was achieved with a tool diameter of 2 mm, the rotational speed of 12,000 rpm, and feed rate of 50 mm/min in which force
and temperature were 14.11 N and 32.45 °C, respectively. The findings of this study can be an excellent help for robotic
surgeries in order to decrease drilling force and temperature and ultimately squeezing of the recovery period.

Keywords Orthopedic surgery · Machining · High-speed bone drilling · Finite element method · Force · Temperature

1 Introduction influential parameters. During drilling, because of contact

between the drill bit and bone and low thermal conductivity
Bone drilling in orthopedic surgeries and dentistry is mainly of the bone (0.38–2.3 J/m s), the temperature raised rapidly
used to keep implant stationery in the patient’s body. Nowa- in the drilling zone [1]. This elevated temperature, higher
days, most of the drilling is done manually to put implants. than the temperature of the human body, causes damage to
The feed rate of the tool is subject to the expertise of the the alkaline phosphatase of the bone, which is ended up in
surgeon. With the ever-increasing application of automation cellular death and thermal necrosis phenomenon. Mechani-
and robots in surgeries, it is required to investigate different cally, implants might be loosened, so elongate the recovery
period [2]. The occurrence of thermal necrosis depends on
the period length and temperature value (44–100 °C) [3].
Technical Editor: Adriano Almeida Gonçalves Siqueira.
It is reported that bone thermal necrosis is very probable
* Mohsen Sarparast when the bone is kept at 47 °C for only a minute, while it
[email protected] immediately happens at 70 °C [4]. In addition to this, apply-
Majid Ghoreishi ing excessive forces pertained to producing more heat can
[email protected] eventuate in either tool breakage or initiation of microcracks
Tohid Jahangirpoor in bone [5]. Thus, lowering both process force and temper-
[email protected] ature can remarkably increase the chance of a successful
Vahid Tahmasbi operation should robotic surgery be used. Profound inves-
[email protected] tigation using both experimental and FE approaches can be
beneficial for better comprehension of the high-speed bone
1
Department of Mechanical Engineering, K. N. Toosi drilling process.
University of Technology, Tehran, Iran
Reingewirtz et al. [6] investigated the correlation between
2
Department of Mechanical Engineering, Arak University, process temperature and rotational speed of the tool found
Arak, Iran

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349 Page 2 of 9 Journal of the Brazilian Society of Mechanical Sciences and Engineering (2020) 42:349

a direct relation in the range of 400- 7000 rpm, while in the Nordin et al. [21], O’Mahony et al. [22], and Vercher et al.
range of 7000–24,000 rpm there is an inverse relation. Above [23] assumed bone as an anisotropic material.
this range, until 40,000 rpm, an approximately constant tem- Considering complicated drilling tool geometry, 3D mod-
perature is reported. Abouzgia et al. [7] studied the bone eling of bone drilling simulation seems unavoidable. David-
drilling process, without a cooling system, on the bovine son and James [24] have reported an analytical–numerical
bone with the rotational speed of up to 49,000 rpm reported model based on machining theories to predict process tem-
that speed rise, up to 40,000 rpm, can cause lower tempera- perature in bone drilling. Wang et al. [25] analyzed ultra-
tures and shorter recovery periods. Heydari et al. [8] stated sonic drilling on fresh bovine bone and compared results
that in lower feed rates, higher temperatures are expected with those of conventional drilling. They related that apply-
due to 1) further contact between drilling tool and bone and ing ultrasonic drilling can significantly reduce process tem-
2) increased thrust forces. Singh et al. [9] studied mainly perature. Tu et al. [26] reported that decreasing the initial
focuses on optimization of drilling parameters like rota- temperature of the bone can reduce drilling zone tempera-
tional speed, feed rate, and the type of tool and observed ture during the process. Sezek et al. [27] developing a 3D
that on increasing the rotational speed, the measured surface FE model found the optimum states of process parameters
roughness was decreasing. Chen et al. [10] used ultrasonic and a safe drilling zone with a temperature lower than 45 °C
vibration during drilling to change drill chip deformation where no thermal necrosis is probable. Khurshid et al. [28]
according to results reported that ultrasonic vibration drill- using a 3D thermo-mechanical FE model investigated the
ing produced thin and smooth chips and increase the surface effect of process parameters for prediction of thermal necro-
roughness of bone. Sarparast et al. [11] optimized the effect sis, and they found that rotational speed is more influential
of different parameters on process temperature and force in than feed rate. Yuan et al. [29] studying the FE model of
high-speed bone drilling and the second-order linear regres- the bone drilling concluded that with higher tool rotational
sion equation of temperature and force according to the input speed process temperature increases remarkably, and ther-
parameters obtained. Shakouri et al. [12] in an experimental mally affected zone increases as well. Lughmani et al. [30]
high-speed bone drilling with a tool diameter of 3.2 mm numerically studied process forces during bone drilling
found increasing speed till 7000 rpm causes a sudden drop using a 3D FE model and found that with a decrease in feed
in machining forces and consequently process temperature. rate and increase in tool rotational speed, process forces can
They considered that setting as an optimum condition. Tah- be fairly reduced. Gok et al. [31] studied thrust power by
masbi et al. [13, 14] studied the bovine bone drilling pro- developing a 3D FE model using a DEFORM-3D software
cess using response surface methodology, reported that with package and achieved numerical results with a good corre-
increase in rotational speed from 500 to 2500 rpm tempera- lation with experimental ones. Rosidi et al. [32] combined
ture of the bone rapidly increases in the drilling vicinity. FE and Taguchi methods to find the optimum parameters
Kadir Gok et al. [15] used a cooling system in bone drilling of tool diameter, feed rate, and tool rotational speed in the
and found it reduces process temperature remarkably. Iyer bone drilling process. Maria et al. [33] have established a 3D
et al. [16] operating over rabbit tibia bone within a range of elastic–plastic FE model in order to decrease the possibility
rotational speed, 2000–400,000 rpm found a reverse cor- of damage to the bone tissue. It was found that the lower is
relation between rotational speed and process temperature. the tool diameter the less is imposing stress of bone tissue.
It was also mentioned that the recovery period is shorter at Generally, considering the results of previous reports, the
higher rotational speeds. Boyne et al. [17] and Moss et al. lack of an appropriate design of experiments and a short-
[18] analyzed high-speed bone drilling process and reported age of a comprehensive model for high-speed bone drilling
lower chances for thermal necrosis in higher rotational process is apparent. It seems that presenting a comprehen-
speeds in comparison with lower rotational speeds. sive FE model which can be able to estimate the behavior
Since most of the studies on bone drilling were limited of process force and temperature as well as the mechanical
to experimental and laboratory investigations, recently, bone fracture is very useful in better understanding of bone
software simulation has attracted researchers. Because the drilling process.
experimental study of the bone drilling process is expen-
sive, time-consuming, and complicated, FE simulation is an
excellent help for the researchers in this field. 2 FE model
Some have focused on bone orthogonal cutting in a 2D
FE analysis. Jacobs et al. [19] investigated the effect of feed There are similarities between bone drilling and drilling
rate and rake angle on-chip deformation and process force. other materials, e.g., metals. Thus, FEM is exceedingly
Alam et al. [20] assuming bone as an isotropic material in helpful to clarify the bone drilling process. In this study,
an orthogonal cutting process studied output parameters like in order to simulate the variation of force and temperature
process force and temperature. Some other reports such as during high-speed bone drilling process a 3D FE model

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Fig. 1  Finite element model of

high-speed bone drilling and
drill bit

Table 1  Drill-bit parameters Table 2  Thermo-mechanical properties of the bone [9, 18]
Symbol Parameter Value Property Value

A Diameter 2 mm Elastic modulus (GPa) 20

B Helix angle 23 ° Thermal conductivity (W/m k) 0.35
C Point angle 118 ° Specific heat (J/kg K) 1260
D Lip height 0.6 mm Density (kg/m3) 2.26*103
E Lip length 1.2 mm Poisson’s ratio 0.35
F Chisel edge angle 130 ° Johnson–cook parameters (A, B, C, n) 50, 101, 0.03, 0.08
G Web thickness 0.4 mm
H Chisel edge width 0.5 mm
and paying attention to the fact that the majority of previous
reports have used bovine bone, in this study fresh bovine femur
was developed in a commercially available FE software bone was used for experimentation. Properties were also used
ABAQUS/Explicit. Bone was modeled as a cylinder with a as an input for the numerical study. Since the anisotropic
height of 5 mm, and a diameter of 6 mm, and the central part behavior of the bone is negligible, in simulations bone tis-
of the bone was partitioned to have more accurate results in sue was assumed as an isotropic and homogenous material.
the drilling zone (Fig. 1). Table 1 displays the drill-bit model Johnson–cook model that usually is used in the simulation
and geometry definitions in the simulation. Since the tool of strain-rate-dependent material was implicated in defining
has higher stiffness than bone, it was modeled as a discrete plastic properties of the bone as presented in Eq. (1) [28].
rigid body. Moreover, due to the dynamic nature of the drill-
𝜀̇ p
ing process, simplifications are great deals in decreasing the
( )
𝜎y = A + B𝜀np (1 + Cln( )) (1)
time of the analysis (Table 2). 𝜀̇ 0

where bone is assumed as an elastic–plastic material and

A, B, C, and n are constant parameters (A is the initial yield
3 Material properties stress, B is the stress coefficient of strain hardening, C is
the strain rate coefficient, and n is the power coefficient of
In this study, there was no access to human bones. Therefore,
strain hardening). 𝜀np, 𝜀̇ p, and 𝜀̇ 0 are plastic strain, strain rate,
considering significant similarities between bovine bone with
and the reference value of strain rate, respectively. Due to
that of humans in terms of physical and mechanical properties

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negligible temperature variation and lack of data on tem- technique with the coefficient of 5 was used in the way that
perature-dependent plasticity for cortical bone tissue in the no significant influence would be exerted on kinetic energy.
bone drilling process, the temperature term was not included All degrees of freedom were constrained on the surface of
in Eq. (1). the bone material, while the tool could rotate around its axis
and move axially. Table 3 lists the input parameters, includ-
ing tool diameter, rotational speed, and feed rate. Moreo-
4 Meshing strategy ver, the initial temperature was assumed to be 20 °C. The
surface to surface contact (standard) algorithm was used in
As depicted in Fig. 1, there are two different meshing zones. the initial step, and the Coulomb friction coefficient of 0.3
The inner part of the bone has 39,903 finite elements of was considered between bone and drilling tool. While heat
(C3D4T) because this is a drilling zone, and precision is generation was considered, all the dissipated energy created
essential. The inner elements were refined using the mesh by friction converted to heat. The fraction of converted heat
refinement method to avoid element distortion during drill- distributed to bone material is set as 0.5 which means that
ing simulation. Less density of elements is considered for only half of this heat is transferred to the bone. The simula-
the outer part with (C3D8T) elements. Using fewer elements tion was performed on an Intel® Core i7 with a 4 GHz of
far from the drilling zone can improve the speed of analysis. CPU and 16 GB of RAM. Figure 2 shows the drilling pro-
The element deletion technique was used to produce and cess and corresponding stress contours.
control hole production. Chip formation was neglected in
the model. Thus, during drilling simulation elements gradu-
ally underwent plastic deformation and when plastic strain 6 Experimentation
reached 0.1 mm the element would be deleted [34].
6.1 Specimen preparation

5 Simulation, boundary condition According to Fig. 3, bovine femur bone with a length of
and interactions 120 mm, and cortical thickness of 5–10 mm was used. In
order to keep the sample fresh, it was taken out from a fro-
In this study, an explicit coupled temperature–displacement zen carcass and kept for two hours in ambient conditions to
step was defined to solve the developed numerical model. maintain mechanical and thermo-physical properties of the
Also, in order to increase analysis speed, mass scaling bone as well as the density of bone tissue. It should be noted
that the flow of inter-tissue fluids and freshness of the bone
is helpful to lower down the bone temperature.
Table 3  Machining parameters used in cortical bone drilling
Experiments Tool diameter (mm) Rotational Feed rate 6.2 Experimental setup
speed (rpm) (mm/min)
As high-speed drilling is defined with rotational speed
1 2 10,000 10
higher than 10,000 rpm, according to Fig. 4, high-speed
2 10,000 30
electrical motor (model Arel TIP: ARFM 1Y-M3) which
3 10,000 50
can continuously provide rotational speeds up to 18,000 rpm
4 12,000 50
was used. It was mounted on the lathing machine, and the
5 14,000 50
drilling tool was set up on it. High-speed steel (HSS) drill
6 18,000 50
bit with a diameter of 2 mm was used for experimental

Fig. 2  FEM simulation of the high-speed bone drilling process and stress contours

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7.2 Thrust force behavior analyses

Figure 5 shows the effect of rotational speed and feed rate on

process force when the drill-bit diameter is 2 mm. As can be
seen from Fig. 5a, feed rate did not remarkably affect pro-
cess force. Increasing feed rate from 10 mm/min to 50 mm/
min, due to high-speed removal of the chip from the hole,
can increase process force only about 0.55 N which is neg-
ligible in comparison with forces during the conventional
bone drilling process. Because this increase is negligible, a
high-speed bone drilling process can be done by high feed
rates to decrease the time of operation.
Figure 5b reveals the remarkable effect of rotational speed
Fig. 3  Fresh bovine femur bone in experimentation on process force. The dispersion of data, here, shows a sig-
nificant influence of the rotational speed. Increasing speed
from 10,000 to 18,000 rpm, due to the smaller size of the
tests, and to minimize the effect of tool wear on test results, chip and higher removal rate, causes a decrease in process
for each set of experiments new tool was used. In order to force from 16.06 to 13.25 N in which this reduction is about
measure temperature k-type thermocouple was installed 17%. This decrease is desirable in terms of the lower pos-
at 0.5 mm distance from the hole wall and with implying sibility of the tool breakage and operation with lower risk.
TM-925 thermometer, the thermocouple was connected to Therefore, increasing rotational speed in bone drilling is
a computer. Temperature can be measured in the range of favorable unless process temperature and thermal necrosis
− 50 up to1300 °C with a resolution of 0.1 °C with a time dictate a limitation.
step of 1 s. Also, the contact area of the thermocouple with
bone was covered with heat sink silicon to decrease thermal 7.3 Temperature behavior analyses
hysteresis and increasing the preciseness of measurements.
For measuring process force, Zemic L6E3 single footing Figure 6 illustrates the effect of feed rate and rotational
load cell was applied. The maximum measurable force with speed on process temperature where the drill-bit diameter
this load cell is 500 N. All experiments were done in ambi- is 2 mm. Presented values for temperature were recorded in
ent temperature similar to orthopedic surgeries. the distance of 0.5 mm from the drilling zone and at the time
of finishing the process when the temperature would be the
maximum. It is worthwhile to notice that in experimenta-
7 Result and discussion tions, there is a limitation in positioning the thermocouple,
while in numerical simulation temperature can be recorded
7.1 Effect of parameters in every arbitrary location of the bone. Furthermore, refer-
ring to previous studies, the area with a temperature lower
To prognosticate the effect of drilling process parameters, than 47 °C was considered safe in terms of thermal necrosis
the behavior of process force, where the temperature is taken possibility. Figure 6a depicts an inverse relationship between
out from numerical simulation, is discussed here. Comparing feed rate and process temperature. With increase in feed rate
the experimental and numerical results proves the maximum from 10 to 30 mm/min, temperature shows a reduction of
discrepancy of 7.2% and 8.5% for process force and tem- 3%. Moreover, increase in the feed rate from 30 to 50 mm/
perature, respectively, and the results show high reliability. min causes an only 1% reduction in process temperature.

Fig. 4  High-speed bone drilling

experimental set up [11]

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Fig. 5  The behavior of process force with variations in a feed rate and b rotational speed

Fig. 6  Process temperature with variation in a feed rate and b rotational speed

This value proves that with increase in feed rate its effective- speeds of 14000 rpm and 18,000 rpm, process temperature
ness on process temperature gradually decreases. increases to 32.6 °C and 47.3 °C, which is about 8% and 63%
According to Fig. 6b, process temperature is consid- increase in comparison with point C, respectively. Also, to
erably influenced by rotational speed. Generally, with an point C, which is a safe state, temperature between rotational
increase in rotational speed, process temperature increases. speeds of 10,000 rpm and 14,000 rpm is suitable to prevent
This increase in temperature is attributed to higher frictional thermal necrosis possibility. The allowable area in Fig. 6 is
energy emerging in the form of heat. At point C, specified shown with a dashed line with a temperature of 47 °C. With
on the graph, there is a remarkable decrease in process a rotational speed of 18,000 rpm, process temperature is far
temperature. Process temperature at a rotational speed of from this area, which remarkably increases the possibility
10,000 rpm equals 32 °C. Increasing speed to 12,000 rpm, of thermal necrosis occurrence.
temperature shows a decrease of 7% and it reaches 30 °C at In the bone drilling process, the ultimate goal can be
point C, which is the optimum point. Temperature reduction defined as finding an optimum combination of the process
at point C is attributed to a decrease in deformed chip thick- outputs to improve the condition of the surgery. The opti-
ness where chip transforms into powder-like shape, which mum state, according to experimental and numerical results,
increases the chip removal speed from the hole. In total, it occurs when rotational speed and feed rate are selected as
decreases the friction between the drilling tool, chip, and 12,000 rpm and 50 mm/min, respectively. In this state,
hole wall. From point C, apart from the fact that process drilling force and temperature are 14.11 N and 32.45 °C,
force remains constant, higher frictional forces overweigh respectively. Therefore, this setup can be implemented in
the positive effect of fast chip removal; consequently, it robot-assisted surgery with maximum speed and no adverse
only results in higher process temperature. With rotational effect on bone tissue.

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7.4 Validation of numerical simulation center of the bone near the tip of the tool is 34.3 °C, and at
the furthest point, it is 29.5 °C. Based on numerical results,
In this study to validate the numerical approach, the experi- imaginarily, at the position of thermocouple, as it was the
mental and FE results of force and temperature were com- case for experimentation, the temperature is about 30 °C.
pared in all experiments which are mentioned in Table 2. For Figure 8 depicts the process force evolution with the
instance, as shown in Fig. 7, process force and temperature rotational speed of 12,000 rpm, the feed rate of 50 mm/
were investigated with setting up the rotational speed of min, and a tool diameter of 2 mm taken from FE anal-
12,000 rpm, the feed rate of 50 mm/min, and tool diameter ysis. As can be seen, the diagram can be divided into
of 2 mm using numerical simulation. The temperature in the three zones. The first zone, A, is the beginning of the
vicinity of the tooltip is much higher, due to the low thermal tool contact with the bone until complete involvement of
conductivity of the bone. This also causes a rapid increase the drilling tip with bone. In this zone, force expectedly
in temperature with the progress of the process in the drill- increases rapidly. In zone B, since the drilling tool is in
ing zone. At the end of the process, the temperature in the full contact with bone, the process force remains almost

Fig. 7  Temperature distribution during high-speed drilling process with the rotational speed of 12,000 rpm, the feed rate of 50 mm/min, and the
tool diameter of 2 mm

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8 Conclusion

In this paper, the effect of rotational speed and feed rate on

process force and temperature in high-speed bone drilling
was studied using experimental and FE analyses. 3D model
of high-speed cortical bone drilling was developed using the
ABAQUS software package.

• For the first time, the 3D thermo-mechanical elastic–plas-

tic model of the high-speed bone drilling process was
developed to estimate the evolution of the process force
and temperature, and it was validated by experimenta-
tion.
• According to both experimental and numerical results,
the optimum state for both process force and temperature
Fig. 8  Drilling force behavior in high-speed bone drilling process occurs when rotational speed, feed rate, and tool diameter
with the rotational speed of 12,000 rpm, the feed rate of 50 mm/min, are 12,000 rpm, 50 mm/min, and 2 mm, respectively. In
and the tool diameter of 2 mm this setup, process force equals 14.11 N and the process
temperature equals 32.45 °C. The maximum discrepancy
constant. The maximum value of force can be seen in this between experimental and numerical analysis in terms of
zone. Approaching the end of the drilling process and prediction of process force and the temperature was 7.2%
with retraction of the drilling tool process, force subsides and 8.5%, respectively.
quickly again (zone C). The fluctuation in the process • Numerical analysis shows that with an increase in
force, especially for zone B, is due to the dynamics of rotational speed, the process force decreases remark-
the bone-tool contact. The maximum process force in this ably. However, the temperature of the drilling zone first
setup is 14.98 N. decreases with rotational speed up to 12,000 rpm due to
Table 4 compares experimental and numerical results lower chip thickness and higher chip removal rate and
for high-speed bone drilling force and temperature in dif- then increases due to the higher contact surface between
ferent machining conditions. As can be seen from Table 4, drilling tool and bone.
the maximum discrepancies between numerical and exper- • With an increase in feed rate, the process force does not
imental results for process force and temperature are 7.2% change remarkably. However, the temperature of the
and 8.5%, respectively. This error can be aroused due to drilling zone decreases due to less time contact of bone
inaccuracy in experimental measurements, inaccuracies in and tool. Therefore, with an increase in feed rate in the
material properties, and frictional states as inputs to the high-speed bone drilling process, the operation can be
numerical model. In total, there is an acceptable correla- done in the least time scale.
tion between numerical and experimental results.

Table 4  Process force Experi- V (rpm) f (mm/min) D (mm) Temperature Force (N) % Error
and temperature from the ment no (°C)
experimental and numerical
analysis in different machining Exp FE Exp FE Temperature Force
conditions
1 10,000 10 2 35.17 33 14.64 15.51 6.2 6
2 10,000 30 34.63 32.3 14.9 15.76 6.7 5.8
3 10,000 50 34.1 32 15.23 16.06 6.1 5.4
4 12,000 50 32.45 30 14.1 14.98 7.5 6.2
5 14,000 50 34.8 32.6 13.39 14.28 6.3 6.6
6 18,000 50 51.73 47.3 12.35 13.25 8.5 7.2

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Funding The author(s) received no financial support for the research, implant osteotomies. Part I: Relationship between drill speed and
authorship, and/or publication of this article. heat production. Int. J. Prosthodont, 10(5).
17. Boyne PJ (1966) Histologic response of bone to sectioning by
high-speed rotary instruments. J Dent Res 45(2):270–276
Compliance with ethical standards 18. Moss RW (1964) Histopathologic reaction of bone to surgical
cutting. Oral Surg Oral Med Oral Pathol 17(3):405–414
Conflict of interest The author(s) declared no potential conflicts of 19. Jacobs C et al (1974) A study of the bone machining process—
interest to the research, authorship, and/or publication of this article. orthogonal cutting. J Biomech 7(2):131–136
20. Alam K, Mitrofanov A, Silberschmidt VV (2009) Finite element
analysis of forces of plane cutting of cortical bone. Comput Mater
Sci 46(3):738–743
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