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International Journal of Adhesion & Adhesives 22 (2002) 357–365

A three-dimensional finite element model for stress analysis of


adhesive joints
J.P.M. Gonc-alves, M.F.S.F. de Moura*, P.M.S.T. de Castro
#
Departamento de Engenharia Mecanica e Gestao
* Industrial, Faculdade de Engenharia da Universidade do Porto, Rua Dr. Roberto Frias,
4200-465 Porto, Portugal
Accepted 29 April 2002

Abstract

This paper presents a new model for three-dimensional finite element analysis of adhesive joints. The model considers geometric
and material nonlinearities and uses solid brick elements as well as specially developed interface elements. The interface elements
allow the calculation of stresses at the adherend–adhesive interfaces. The application of the model to a single-lap joint is presented.
The results of a linear elastic analysis highlight the three-dimensional nature of the stresses and stress concentrations at interfaces.
The influence of material nonlinearities on the behavior of the joint is also discussed.
r 2002 Elsevier Science Ltd. All rights reserved.

Keywords: C. Stress analysis; Adhesive joints; Interface finite elements

1. Introduction performed linear analysis, and modeled the adhesive


layer with two rows of elements, thus obtaining the
Adhesive bonding is being increasingly used in stress variation across the adhesive thickness. Many
structural applications. The characteristics of adhesive other two-dimensional models of single-lap joints
joints make them attractive in industries such as followed this work. Similar linear analyses were done
aeronautics, automotive and civil engineering. When by Guess et al. [3]. They used a more refined mesh,
compared to mechanically fastened joints, adhesive which allowed them to identify significant stress
joints have the advantages of having less sources of gradients across the adhesive thickness. Harrison and
stress concentrations, more uniform distribution of Harrison [4] did a simplified analysis in which they
load, and better fatigue properties. considered rigid adherends and studied the adhesive
The increased application of adhesive joints was deformations. Adams and Peppiatt [5] used plane strain
accompanied by the development of mathematical triangular elements to model a single-lap joint and
models to analyze the behavior of those joints. Both considered the adhesive layer to have either a square
analytical and numerical models have been developed. edge or a spew fillet.
Analytical models such as the classical work by Goland Two-dimensional models that incorporate nonlinea-
and Reissner [1] usually involve some simplifying rities were also developed. Cooper and Sawyer [6]
assumptions. However, some of those models yield considered geometric nonlinearities in their model. A
closed-form solutions. similar analysis was performed by Tsai and Morton [7].
Among the numerical models, the finite element Harris and Adams [8] incorporated material and
method has been extensively used. The single-lap joint geometric nonlinearities in their analysis. They used
has been used in most of the studies due to its simplicity triangular and quadrangular plane strain elements and
and practical application. One of the first finite element modeled the spew fillet at the end of the adhesive layer.
analyses of a single-lap joint was published by Wooley Several special elements to model the behavior of the
and Carver [2]. They used plane stress elements, adhesive layer were developed. Barker and Hatt [9]
published one of the earlier works in this area. They
*Corresponding author. Fax: +351-2220-59125. developed a four-node element for two-dimensional
E-mail address: mfmoura@fe.up.pt (M.F.S.F. de Moura). analysis that behaves like a spring with normal and

0143-7496/02/$ - see front matter r 2002 Elsevier Science Ltd. All rights reserved.
PII: S 0 1 4 3 - 7 4 9 6 ( 0 2 ) 0 0 0 1 5 - 5
358 J.P.M. Gonc-alves et al. / International Journal of Adhesion & Adhesives 22 (2002) 357–365

shear stiffnesses, which are dependent on the thickness elements based on displacements do not satisfy the
of the adhesive layer. Carpenter [10] developed a simple continuity of the stress vector at the interfaces. Cheikh
element that considered the adhesive with no thickness. et al. [22] proposed a technique, based on the finite
Later, the same author [11] developed another element element method formulated in terms of displacements
that considers the adhesive thickness and a linear that enables stress conditions to be imposed. They used
variation of the displacement field across it. Carpenter two-dimensional analysis and applied their technique in
and Barsoum [12] developed two specific elements that the study of the stress distributions at the adherend–
incorporate some assumptions used in several analytical adhesive interfaces.
studies. These elements can be used with two-dimen- In this paper, a new model for three-dimensional finite
sional plane stress or plane strain elements, as well as element analysis of adhesive joints is presented. The
with shell or beam elements. Rao et al. [13] developed a model considers the stress variation across the adhesive
six-node isoparametric element similar to the one thickness as well as geometric and material nonlinea-
presented in [9]. Yadagiri et al. [14] modified that rities. Adherends and adhesive are represented by solid
element to include longitudinal normal stresses and brick elements and the interfaces are modeled by special
viscoleastic analyses. Lin and Lin [15] introduced an interface elements. Interface elements are included in
element that represents both the adhesive layer and the order to allow the calculation of stresses at the
adherends and that is based on Timoshenko’s beam adherend–adhesive interfaces. The application of the
theory. Reddy and Roy [16, 17] developed a special model to a single-lap joint is presented. The results
element for geometric and material nonlinear analyses. highlight the three-dimensional nature of the stresses
All the finite element analyses referred to above are and the influence of material nonlinearities on the
two-dimensional. However, even for a simple adhesive behavior of the joint.
joint such as the single-lap joint, stresses are of three-
dimensional nature. This was investigated by Tsai and
Morton [18] who performed three-dimensional linear 2. Interface finite element
elastic finite element analysis of a single-lap joint in
which boundary conditions account for the geometric An interface finite element for three-dimensional
nonlinear effects. These authors showed that three- analysis has been previously developed [23, 24]. It
dimensional regions exist in the specimen. They showed consists of 18 nodes distributed in two faces as shown
that the adherend and adhesive stress distributions in in Fig. 1. The element has zero thickness and is
the overlap, near the free surface, are quite different compatible with 27 node isoparametric hexahedral
from those occuring in the interior. Pandey and elements available in the ABAQUSs software [25]. Its
Narasimhan [19] also contributed to the identification formulation can be viewed as a contact problem as
of the three-dimensional nature of stresses in adhesively detailed below.
bonded single-lap joints by performing three-dimen-
sional viscoplastic analysis considering material and
geometric nonlinearities. 2.1. Theory
Special elements that model the adhesive layer were
also developed for three-dimensional analyses. Edlund The equilibrium equations of a structural problem
and Klarbring [20] developed an element for geometric involving contact can be formulated as the minimization
nonlinear analysis. They assumed that the adhesive layer of the potential energy subjected to certain kinematic
is of negligible thickness and has linear elastic behavior. constraints. Considering the variational method and
Andruet et al. [21] developed a model for three- using the penalty function method, the potential energy
dimensional analysis of adhesive joints based on shell
and solid elements. The shell elements are used to model
the adherends and the adhesive layer is modeled as a 16
solid element with offset nodes in the mid-planes of the 15
adherends. The element formulation includes geometric 17
7
nonlinearities, and thermal and moisture effects. 14
18 6
In addition to considering the three-dimensional 10 8 13
nature of adhesive joints, the calculation of accurate 11 9 5
stresses at the adherend–adhesive interfaces is of
primary concern. The failure of adhesive joints usually 1 12 4
occurs in the adhesive (cohesive failure) or at the 2
adherend–adhesive interfaces (adhesive failure). More-
3
over, cohesive failure usually occurs near the adherend–
adhesive interface. However, conventional finite Fig. 1. The interface element.
J.P.M. Gonc-alves et al. / International Journal of Adhesion & Adhesives 22 (2002) 357–365 359

can be written as or, including the differentiation of (2)


" #
e Xd X
d
pðUÞ
% ¼ pðUÞ þ ½GðUÞ&2 ; ð1Þ T T
2 Kþe C k nk nk C k U ¼ F ' e g k C k nk ð10Þ
k¼1 k¼1
where
or
pðUÞ ¼ 12UT KU ' UT F; ð2Þ
½K þ Kr &U ¼ F þ Fr ð11Þ
pðUÞ being the functional of a structural problem
without constraints, pðUÞ the functional of a structural in which
%
problem with kinematic constraint, U the displacement X
d

vector, K the stiffness matrix, F the nodal forces, Kr ¼ e Ck nk nTk CTk ; ð12Þ
GðUÞ ¼ 0 the kinematic constraint, and e the penalty k¼1

parameter. X
d
The kinematic constraint for a pair (k) of homologous Fr ¼ 'e g k C k nk : ð13Þ
points is [26, 27] k¼1

ðU2i ' U1j Þ ( nk þ gk ¼ 0; ð3Þ It can be stated that Kr and Fr represent the
contribution of the constraints to the global problem.
where U2i ; U1j are the displacement vectors of two Thus, the interface finite element formulation is the
homologous points (i and j) belonging to the two determination of its contribution to the global problem
contacting bodies (1 and 2), nk the unit vector normal to by matrices Kr and Fr :
the contact surface, and gk the initial distance in the
normal direction n between two homologous points (i 2.2. Stresses at the interfaces
and j) belonging to the two contacting bodies.
The equilibrium state is obtained from the minimiza- Contrary to continuum elements where stress–strain
tion of Eq. (1) relative to the displacement field (U). It relationships are used, interface elements are governed
can be shown that, when e approaches infinity, the by stress-relative displacements relationships. The
minimization of the functional pðUÞ
% produces a better vector of relative displacements between two
approximation of GðUÞ ¼ 0: The vectors U2i and U1j can homologous points can be obtained from the displace-
be written ments fields associated with the element faces (top and
U2i ¼ eTi U; ð4Þ bottom)
8 9 8 9 8 9
< ds >
> = > < us >
= < us >
> =
U2j ¼ eTj U; ð5Þ d ¼ dt ¼ ut ' ut ; ð14Þ
: >
> ; > : > ; : >
> ;
where ei and ej are the three columns of the identity dn un top un bot
matrix that allow the calculation of the displacement
where s and t represent the tangential directions and n
vector of the homologous points i and j; respectively.
the normal direction. The displacements in the local
Eq. (3) can be rewritten as
directions (normal and tangential to the contact surface)
ðCTk UÞ ( nk þ gk ¼ 0; ð6Þ can be obtained from the generalized displacements
doing
where 8 9 8 9
< us >
> = <u>
> =
CTk ¼ eTi ' eTj : ð7Þ T
ut ¼ h v ; ð15Þ
: >
> ; : >
> ;
Considering the total number of constraints (d), the un w
functional for the problem being treated can be obtained
as where
h ¼ ½Vs ; Vt ; Vn &: ð16Þ
pðUÞ
% ¼ pðUÞ
Vs ; Vt and Vn are the unit vectors of the local directions
eXd
þ ½ððCTk UÞ ( nk þ gk ÞT ððCTk UÞ ( nk þ gk Þ&: ð8Þ (see Fig. 2) and are obtained from
2 k¼1 8 9
> qx >
>
> >
Minimizing this equation leads to > qx >
> >
>
< qy >
> =
dpðUÞ
% ¼ dpðUÞ Vx ¼ ; ð17Þ
>
> qx >
X
d > >
> >
>
> >
þe ½UT Ck nk nTk CTk þ gk nTk CTk &dU ¼ 0 ð9Þ : qz >
> ;
k¼1 qx
360 J.P.M. Gonc-alves et al. / International Journal of Adhesion & Adhesives 22 (2002) 357–365

η units are N/m3 and they represent the penalty parameter


Vn
6 introduced by the user. These parameters have to be
carefully chosen in order to obtain a good performance
7 Vt
5 of the model. As small values induce large interpenetra-
8 tions incompatible with the physical reality while large
9 Vs
4 ξ values produce numerical problems, the optimum inter-
face stiffnesses are the largest values that do not produce
2 3
1 numerical problems.
Fig. 2. Local directions (x; Z) and unit vectors (Vs ; Vt ; Vn ).

3. Model of a single-lap joint


8 9
> qx > The model of a single-lap joint is presented in this
>
> >
>
>
> qZ >
> section. The joint considered is represented in Fig. 3.
>
> >
< qy >
= The mechanical properties of the adherends and
VZ ¼ ð18Þ adhesive are given in Tables 1 and 2, respectively. The
>
> qZ >
>
>
> >
> geometry and boundary conditions of the model are
>
> qz >
> >
: >
; shown in Fig. 4. The model represents only half of the
qZ joint due to the longitudinal symmetry. A detail of the
in the following way: mesh used is given in Fig. 5. The mesh consists of 2720
Vx solid elements of 20 nodes (reference C3D20 [25]), 1360
Vs ¼ ; ð19Þ solid elements of 27 nodes (reference C3D27 [25]), and
jVx j
544 interface elements. The interface elements are placed
Vx ) VZ at the adherends–adhesive interfaces. The solid elements
Vn ¼ ; ð20Þ
jVx j jVZ j adjacent to the interfaces have 27 nodes and the
remaining are 20 node solid elements. Each adherend
Vt ¼ Vn ) Vs : ð21Þ is modeled with four layers of elements across its
The stresses at interfaces are obtained from the thickness and the adhesive is represented by three layers
relative displacements and are given by of elements.
Two different analyses were performed using
tsn ¼ ks ds ; the above model. Linear elastic and elasto-plastic
ttn ¼ kt dt ; ð22Þ
Table 1
snn ¼ kn dn : Mechanical properties of adherend
Eq. (22) can be written in matrix form E (MPa) n smax (MPa) emax (%)
r ¼ Dd; ð23Þ 62,088 0.30 124.1 14.0
where
2 3
ks 0 0
6 7
D¼40 kt 0 5: ð24Þ Table 2
Mechanical properties of adhesive
0 0 kn
E (MPa) n s0:2 (MPa) smax (MPa) emax (%)
The parameters ks and kt are the shear interface
437.4 0.38 12.7 15.0 11.3
stiffnesses and kn is the normal interface stiffness. Their

Adhesive

Adherend 1.5
0.25
Adherend 1.5

25 87.5 12.5 87.5

Fig. 3. Single-lap joint with dimensions in mm.


J.P.M. Gonc-alves et al. / International Journal of Adhesion & Adhesives 22 (2002) 357–365 361

C D
B x
A

Fig. 4. Geometry and boundary conditions of the model.

plane closer to the longitudinal symmetry plane are


higher than the other stress components. The sxx and szz
stresses are of the same order of magnitude.
Fig. 6(d) shows the distribution of the shear stress txy :
This stress distribution does not change significantly
across the joint width, which means that this stress
component is less sensitive to the three-dimensional
effects. The stress txz ; presented in Fig. 6(e) is zero at the
longitudinal symmetry plane. For other planes, there are
peaks near the ends of the overlap. These peaks are
increasingly higher for longitudinal planes closer to the
joint edges. The stress tyz ; shown in Fig. 6(f), is also zero
at the longitudinal symmetry plane and the peak
increases with the z coordinate. It should be noted that
Fig. 5. Detail of finite element mesh.
the three-dimensional effect for the two last stress
components (txz and tyz ) is present across all the joint’s
material models were considered for the adhesive and width. This is contrary to what happens with the normal
adherends. Geometric nonlinearity was considered in all stress components where the three-dimensional effect is
analyses. only present near the edges.
The stresses at the interfaces were also studied.
3.1. Linear elastic materials Figs. 7(a)–(c) show the stresses at the upper interface
(y ¼ 0:125 mm). It must be noted that the stresses are
A finite element analysis was performed considering plotted along longitudinal planes that are different from
an applied static force of 1.8 kN. The stress distributions the ones considered in Fig. 6. This happens because the
at the middle of the adhesive thickness are presented integration points of the interface element coincide with
in Fig. 6. Each graph in Fig. 6 represents the long- the pairs of homologous nodes. This is due to the
itudinal distribution of a normalized stress component Newton–Cotes integration scheme used, which has been
along the overlap length in several longitudinal planes shown to have the better performance concerning stress
(planes z=constant in Fig. 4). The average shear stress oscillations [24].
at the adhesive is used to normalize the stress As observed for the normal stress components in the
components. middle of the adhesive layer, the normal stress syy at the
In Fig. 6(a), the sxx normal stress component is interface is almost constant across the joint width, but
plotted. Its maximum value occurs close to the ends of decreases near the edges. In Fig. 7(a) it can be seen that
the overlap, at the longitudinal plane that is nearest to the maximum stress syy occurs at the end of the overlap
the symmetry plane (z ¼ 0:176 mm). The sxx distribu- (point D in Fig. 4) and at the symmetry plane
tion is almost constant across the joint width but (z ¼ 0 mm). As it can be seen in Fig. 7(b), the shear
decreases significantly near the edge (z ¼ 12:324 mm). stress txy has a similar behavior. It must be noted that
That effect is also verified for the syy and szz these two stress components have peak values that are
components shown in Figs. 6(b) and (c), respectively. much higher than the ones in the middle of the adhesive
The syy stresses at the ends of the overlap and in the layer. The shear stress tyz at the interface and in the
362 J.P.M. Gonc-alves et al. / International Journal of Adhesion & Adhesives 22 (2002) 357–365

1.5 3

2.5 z = 0.176 mm
z = 0.176 mm
z = 6.426 mm z = 6.426 mm
1 2
z = 10.761 mm z = 10.761 mm
z = 11.719 mm 1.5 z = 11.719 mm

σyy /τ average
σxx/τ average

z = 12.324 mm z = 12.324 mm
0.5 1

0.5

0 0
_0.5

_ 0.5 _1

(a) 0 2 4 6 8 10 12 14 (b) 0 2 4 6 8 10 12 14
x (mm)

1.5 2.5

z = 0.176 mm z = 0.176 mm
z = 6.426 mm z = 6.426 mm
1 2
z = 10.761 mm z = 10.761 mm
z = 11.719 mm z = 11.719 mm
xy average
σzz /τ average

z = 12.324 mm z = 12.324 mm
0.5 1.5
τ /τ

0 1

_0.5 0.5
0 2 4 6 8 10 12 14 0 2 4 6 8 10 12 14
(c) x (mm) (d) x (mm)

0.06 0.8
z = 0.176 mm z = 0.176 mm
z = 6.426 mm 0.6 z = 6.426 mm
0.04
z = 10.761 mm z = 10.761 mm
z = 11.719 mm 0.4 z = 11.719 mm
0.02 z = 12.324 mm z = 12.324 mm
0.2
τ yz /τ average
τxz /τ average

0 0
_0.2
_0.02
_0.4
_0.04
_0.6

_0.06 _0.8

0 2 4 6 8 10 12 14 0 2 4 6 8 10 12 14
(e) x (mm) (f) x (mm)

Fig. 6. (a) Normalized stress sxx at the middle of the adhesive thickness. (b) Normalized stress syy at the middle of the adhesive thickness. (c)
Normalized stress szz at the middle of the adhesive thickness. (d) Normalized stress txy at the middle of the adhesive thickness. (e) Normalized stress
txz at the middle of the adhesive thickness. (f) Normalized stress tyz at the middle of the adhesive thickness.

middle of the adhesive layers (see Figs. 6(f) and 7(c)) static force of 2.9 kN. A different yield criterion was
have similar distributions. used for each material. The Von Mises yield criterion
was used for the adherends, and the Raghava et al. [28]
3.2. Elasto-plastic materials parabolic criteria was used for the adhesive. This
criterion can be written as
Taking into consideration the elasto-plastic materials’
ðs1 ' s2 Þ2 þ ðs2 ' s3 Þ2 þ ðs3 ' s1 Þ2
behavior, a material and geometric nonlinear finite
element analysis was performed considering an applied þ 2ðjsc j ' st Þðs1 þ s2 þ s3 Þ ¼ 2jsc jst ; ð25Þ
J.P.M. Gonc-alves et al. / International Journal of Adhesion & Adhesives 22 (2002) 357–365 363

12 8

10 7 z = 0 mm
z = 0 mm
z = 6.25 mm z = 6.25 mm
8 6
z = 10.156 mm z = 10.156 mm
z = 11.719 mm 5 z = 11.719 mm
6

τxy /τ average
yy average

z = 12.5 mm z = 12.5 mm
4 4
σ /τ

2 3

0 2

_2 1

_4 0
0 2 4 6 8 10 12 14 0 2 4 6 8 10 12 14
(a) x (mm) (b) x (mm)

0.8
z = 0 mm
0.6 z = 6.25 mm
z = 10.156 mm
0.4
z = 11.719 mm
z = 12.5 mm
0.2
τ yz /τ average

0
_0.2

_0.4

_0.6

_0.8
0 2 4 6 8 10 12 14
(c) x (mm)

Fig. 7. (a) Normalized stress syy at the interface y ¼ 0:125 mm. (b) Normalized stress txy at the interface y ¼ 0:125 mm. (c) Normalized stress tyz at
the interface y ¼ 0:125 mm.

where s1 ; s2 and s3 are the principal stresses, and sc and In Figs. 10(a) and (b), the normalized stresses syy and
st are the compression and tensile strengths, respec- txy at the upper interface (y ¼ 0:125 mm) and obtained
tively. In this criterion, a ratio of 1.3 between the at the maximum load (P ¼ 2:9 kN) are presented. The
compression and tensile strengths was assumed. The peak value of the normalized stress syy varies between
progressive plastification of the materials was analyzed 1.8 kN (z ¼ 0:0 mm) and 3.8 kN (z ¼ 12:5 mm) and an
at several stages of the loading history. In Figs. 8(a) and almost constant behavior is observed for the txy
(b) a schematic representation of the plastic zones in the normalized stress. As expected, a general decrease of
adhesive layer is presented for two different load levels. stress levels is observed relative to the linear case (see
The gray element faces show that at least some of the Figs. 7(a) and (b)).
integration points closer to those faces have plastified.
In Fig. 8(a) it can be seen that the plastification starts at
the ends of the adhesive layer (points A and D in Fig. 4). 4. Conclusions
Fig. 8(b) shows that the plastification grows toward the
longitudinal symmetry plane and across the adhesive A new three-dimensional finite element model for
thickness. studying the behavior of adhesive joints is presented.
The maximum normalized stresses syy and txy at the The model includes an interface element previously
upper interface (y ¼ 0:125 mm) for different load levels developed that is compatible with brick solid elements
are presented in Fig. 9. It can be stated that the peak from the ABAQUSs software. The main objective was
normalized stresses decrease as the applied load to calculate the stresses at the interfaces between
increases. Also, for the higher load levels the peak adherends and adhesive, which are considered critical
normalized stresses shift from the symmetry plane to the regions in these structures. An application to single-
free edge. lap joints was performed considering two different
364 J.P.M. Gonc-alves et al. / International Journal of Adhesion & Adhesives 22 (2002) 357–365

σyy/τ average
_2 z = 0 mm
z = 6.25 mm
z = 10.156 mm
_4 z = 11.719 mm
z = 12.5 mm
_6
0 2 4 6 8 10 12 14
(a) x (mm)

z = 0 mm
3 z = 6.25 mm
z = 10.156 mm
z = 11.719 mm
τxy /τ average 2 z = 12.5 mm

Fig. 8. Simplified representation of the adhesive plastic zone for (a) _1


P ¼ 1:2 kN, (b) P ¼ 2:1 kN.
0 2 4 6 8 10 12 14
(b) x (mm)

12 Fig. 10. (a) Normalized stress syy at the interface y ¼ 0:125 mm for
P ¼ 2:9 kN. (b) Normalized stress txy at the interface y ¼ 0:125 mm for
Max (σ /τ ) P ¼ 2:9 kN.
10 yy average
Max (τ /τ )
Max (normalized stress)

xy average

8
much higher than at the middle of the adhesive layer.
6 This can explain why the interfaces are critical regions
regarding adhesive joints failure.
4 The analysis with elasto-plastic materials’ behavior
z = 10.938 mm
z = 12.5 mm

z = 12.5 mm

was performed in order to include a more general


z = 0 mm

z = 0 mm

z = 0 mm

z = 0 mm

z = 0 mm

z = 0 mm

z = 0 mm

2 situation. In this case, a general decrease of the


normalized stresses at interfaces as the load grows was
0
observed. As expected, the plastification induces a
0.6 1.2 2.1 2.4 2.9
decrease of the stress concentrations in the critical
P (kN) regions.
In future work, this model will be used to predict the
Fig. 9. Change of the maximum value of normalized stresses syy and
txy at the interface y ¼ 0:125 mm. strength of adhesive joints. For that, the interface
elements must include a specific damage model to
simulate damage initiation and propagation and their
approaches: linear elastic and elasto-plastic materials’ influence in the global structural behavior.
behavior.
In the linear elastic case, the three-dimensional nature
of the stresses is demonstrated. This strongly suggests Acknowledgements
that the bi-dimensional models must be carefully used in
the strength prediction of adhesive joints. It was also This paper was finalized in the context of FCT project
observed that the peak stresses at the interfaces are EME 35975/99 (POCTI/43525/EME/2000-ERDF).
J.P.M. Gonc-alves et al. / International Journal of Adhesion & Adhesives 22 (2002) 357–365 365

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