Stamping 101: How does a hydraulic press work?
Stamping 101: How does a hydraulic press work?
Presses of all typesmechanical, pneumatic, servo, and hydraulichave their place and offer unique advantages. However, over the past 50 years, hydraulic presses have trended toward greater utility. Today's hydraulic presses are faster and more reliable than ever, and the technology has gone through significant changes and refinements. Improvements in seals, pumps, hoses, and couplings have nearly eliminated leaks and minimized maintenance.
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An examination of hydraulic press technology and the presss anatomy, as well as its benefits, limitations, tips for selection, and automation options, can net the best utility from a press.
Hydraulic Press Anatomy, Types
Press Structure. These are the major components and features of the hydraulic press structure:
1. Cylinder. The cylinder assembly comprises a cylinder, piston, ram, packing, and seals. Piston diameter and oil pressure determine the force (tonnage) that a press can deliver.
2. Frame. The frame is the main structure of the press containing the cylinders and the working surfaces.
3. Stroke Control. Stroke length can be set for any distance within the stroke limits of the cylinder in the stroke control. Adjustments include the top of stroke, pre-slowdown point, and bottom of stroke.
4. Throat Clearance. The distance from the vertical centerline of the ram to the frame member behind the bed is called the throat clearance. This distance determines the maximum piece size that can be positioned with the part centerline under the center of the ram.4.The distance from the vertical centerline of the ram to the frame member behind the bed is called the throat clearance. This distance determines the maximum piece size that can be positioned with the part centerline under the center of the ram.
5. Daylight. This is the vertical clearance from the top of the bolster to the underside of the ram in its maximum up position. This term is sometimes confused with the mechanical press term shut height. Shut height is the clearance over the bed with the ram fully down. Daylight describes the maximum vertical die capacity of the press.
6. Bed. The bed is the flat, stationary machined surface that supports the bolster and dies.
7. Bolster. This is a plate or structure mounted on the bed that the tooling is mounted and attached to. Most hydraulic presses are constructed so that the bolster is removable.
8. Dual Palm Button Controls. This is a common method of actuating hydraulic presses. Both buttons must be depressed at the same time to bring the ram down, requiring the operator to use both hands. Control circuits include nonrepeat and anti-tiedown features.
9. Work Height. The distance from the floor to the top of the bolster is the work height.
Type of Frames. Many of these hydraulic frame types are common with mechanical press frames:
- Bench. Compact and economical, a bench press is fast and easy to set up. It is used in a range of jobs, from single-cycle operations to automated cell components. Generally, its tonnage capacity is from 3 to 50.
- C-frame. An open-gap, C-frame press is built for long service in multishift industrial production applications in 10- to 500-ton capacities. It is called a C-frame because of its C shape. This type of frame tends to yawn. Applications that cannot withstand this yawning characteristic should be moved to another style of press, such as a four-post or straight-side (see lead image).
Four-post. This heavy-duty production press is built for continuous operation. It uses four heavy-duty, large-diameter, shouldered columns to tie the frame together. These large-diameter columns precision-guide the moving platen or press slide. This ensures exceptionally consistent upper and lower die alignment, minimizes deflection, and eliminates "lean-back." Any deflection that does occur in this style of press is straight up and down. It also enables loading of the press from any of the four sides, permitting easy integration into production lines and manufacturing cells.
- Straight-side. Designed to meet the most demanding application requirements, a straight-side press has a superior frame construction. Generally, the press is built with a crown, slide, and bed weldment that is bolted, welded, or tie-rodded to large slabs of steel, called side plates. Unlike a four-post construction in which the frame is built entirely of the four columns, a straight-side press is supported by the two steel slab side plates and tie rods to reduce the amount of stretch in the frame under load. Heavy-duty blanking typically requires the tie-rodded construction to withstand the severe shock at material breakthrough. The press can run at high speeds and is capable of millions of cycles per year.
- Gib-guided. A gib-guided press is designed to counter the effects of off-center loading. Rigid steel frames with gib-guided slides maintain parallelism under severe loading conditions.
- Air-over-oil. An air-over-oil press has a four-post construction. It applies force in a vise-like grip for seconds, minutes, or hours, maintaining tonnage for nearly any length of time with the help of an air compressor. It is used mainly for lamination work. It is also suitable for applications that require a force on the product for long periods of time. It is not suitable for typical stamping applications as it has a single-acting cylinder and not conducive for applications that require any pullout/stripping tonnage. It is also upacting, which usually is not very useful for most conventional applications. With a low initial price and minimal operating costs, this press has the force of a conventional hydraulic press at a fraction of the cost.
- Custom. When a standard press design does not adequately meet your needs, a press tailored to your application may be in order.
Hydraulic Press Common Terms and Features
Being familiar with these terms will enhance your understanding of a hydraulic press:
- Blank Holder: A controlled force to hold the edges of the blank in a deep-drawing operation, similar to a die cushion.
- Die Cushion: A hydraulic or air cylinder positioned below the bolster and bed, providing uniform blank holding in deep drawing. Cushions also strip finished parts from the punch or die.
- Distance Reversal Switch: An adjustable limit switch to set the depth of stroke at which the ram reverses.
- Dwell Timer: An adjustable timer to set the length of dwell at the bottom of the stroke. The timer may be used for other functions such as timing a sequence of press movements.
- Heat Exchanger: A device attached to the oil reservoir to circulate water or air to keep oil at the proper operating temperature.
- Knockout: A device that strips the part from the punch or die.
- Platen: A plate, sometimes heated, attached to a moving or stationary press member.
- Pressure Reversal Switch: An adjustable switch to set the pressure at which the ram reverses.
Hydraulic Press Advantages
- Time Savings During Setup, Changeovers. Because the full power of a hydraulic press can be delivered at any point in the stroke, there is no need to determine the exact location of maximum tonnage.
- Flexibility for a Range of Applications. One hydraulic press can do many jobs within its tonnage range, including high-volume production. Common applications are deep draws, shell reductions, urethane bulging, forming, blanking, piercing, staking, punching, straightening, assembly, and press fits. They are also used for powdered metal forming, abrasive wheel forming, bonding, broaching, ball sizing, plastic and rubber compression, and transfer molding. A press fit is used for pushing a bearing onto a shaft without any mechanical fasteners to keep it in place. Typically, the hole in the bearing is several thousandths of an inch smaller than the diameter of the shaft that it is pressed onto, allowing for a nonmoving or rotating press fit.
Also, programmable logic controllers (PLCs) and other electronic-based controls have improved a hydraulic presss speed and flexibility. With new computer interfaces and monitoring, hydraulic presses can be used in advanced computer-integrated manufacturing systems.
- Built-in Overload Protection. This eliminates worries about overloading or breaking the press or smashing a die. When a hydraulic press reaches its set pressure, that's all the pressure there is. The relief valve opens at that limit and there is no danger of overload.
The built-in overload protection applies to the tools too. If they are built to withstand a certain load, there is no danger of damaging them because of overloading. Tools can be sized to withstand the load of a particular job, not a particular press. The pressure of the press can be set to suit the job. The lack of impact, shock, and vibration promotes longer tool life.
- Lower Operating Costs, Increased Uptime. Hydraulic presses are relatively simple with just a few moving parts, and these are fully lubricated in a flow of pressurized oil. Breakdowns are infrequent, but when they do occur, they usually are minor. Typical routine maintenance items include replacements of packing, solenoid coils, and occasionally a valve. Not only are these parts inexpensive, but they are also easily replaced without having to disassemble the entire machine.
- Larger Capacities for Minimal Cost. Compared to a typical mechanical press, it is easier and less expensive to buy certain kinds of capacity in a hydraulic press with common stroke lengths of 12, 18, and 24 in., and it easily can be equipped with extra stroke length. Open gap (daylight) can be added as well for a minimal cost. Similarly, hydraulic presses can be built with larger table areas and beds, or smaller beds than are standard. The press tonnage doesn't dictate what the bed size will be.
- Great Control. With a hydraulic press, the ram force, direction, speed, release of force, and duration of pressure dwell can all be adjusted to fit a particular job.
- Low Noise Level. Few moving parts and the absence of a flywheel equate to an overall low noise level. Because each phase of the ram movement can be controlled, noise levels also can be controlled. A hydraulic ram can be programmed to pass through the work slowly and quietly.
- Safety. Because ram movements can be controlled, its easy to make movements safe. Non-tiedown, anti-repeat, and dual-palm button controls are used to enhance safety. The interlocking of guards, as well as other safety devices, is relatively easy because of the nature of a hydraulic press control system.
Hydraulic Press Limitations
- No hydraulic press today is as fast as the fastest mechanical press. If speed is the sole requirement and the material feed stroke is relatively short, a mechanical press remains the best choice.
- Stroke depth is a key factor to consider. If a limit switch is used to determine the bottom, the stroke depth is not likely to be controlled much closer than 0.020 in. Many hydraulic presses can be set to reverse at a preselected pressure, which usually results in uniform parts.
- Generally, if absolute stroke depth accuracy is required, "kiss" blocks must be provided in the tooling. However, some hydraulic presses are now available with an accurate built-in method of limiting the downstroke. New closed-loop servo-hydraulic systems dramatically improve stroke depth control, guaranteeing consistent, repeatable results. In many applications, this system eliminates the need for kiss blocks
- A hydraulic press requires some external or auxiliary power to feed stock. The feeder must have its own power and be integrated with the press control system. However, an increasing selection of self-powered feeding systems are available as roll feeds, hitch feeds, and air feeds.
- Both mechanical and hydraulic presses experience shock after breakthrough during blanking. But the hydraulics of a hydraulic press also must be isolated from the shock associated with decompression. If the hydraulic system does not contain an antishock feature, this shock can affect the lines and fittings.
Which Type of Hydraulic Press Is Best for My Application?
Open-gap presses provide easy access from three sides. Four-column presses ensure even pressure distribution. Straight-side presses offer the rigidity required for off-center loading in progressive die applications. One important thing to keep in mind is that the more critical the work and the more demanding the tolerances, the greater the reserve tonnage capacity should be.
Once the basics are determined, the next consideration is to select options. Most hydraulic press builders offer an array of accessories such as:
- Distance reversal limit switches.
- Pressure reversal hydraulic switches.
- Automatic (continuous) cycling.
- Dwell timers.
- Sliding bolsters and rotary index tables.
- Die cushions.
- Ejection cylinders or knockouts.
- Electronic light curtains and other safety devices.
- Touchscreen controls.
- Servo system feedback for precise, consistent, repeatable stroke control.
Note that the hydraulic circuit for a press is determined mainly by the application. In long-stroke applications such as deep-drawing, a dual-pump circuit with regeneration is typical. This allows the press ram to move quickly down to the work and out of the work while enabling a smooth draw speed.
However, when you are stamping on a hydraulic press, it is best to minimize how many valves you use during what is typically a very short stroke. Most presses used for stamping employ only a single hydraulic pump because of the short stroke required. This setup allows for fewer valve shifts, which reduces cycle time for a complete stroke and allows for many more strokes per minute.
Quality can vary greatly from press to press. Some light-duty presses are capable of "spanking" the work momentarily and reversing, and there are heavy-duty machines designed for general-purpose metalworking applications.
A few constructive points can be used to compare one machine with another:
Frame: Look at frame constructionrigidity, bolster thickness, dimensional capacity, and other factors. Cylinder: What diameter is it? How is it constructed? Who makes it? How serviceable is it? Maximum system pressure: At what PSI does the press develop full tonnage? The most common range for industrial presses is 1,000 to 3,000 PSI. Horsepower: The duration, length, and speed of the pressing stroke determine the horsepower required. Compare horsepower ratings.
Speed: Determine the speed each hydraulic press offers.
Designing the Press: Selection Tips
Press Tonnage. The tonnage required to do a job and the formulas to determine it is the same for hydraulic presses and mechanical presses. The tooling usually is interchangeable. There may be certain applications such as deep drawing in which the full power stroke characteristic of a hydraulic press reduces the tonnage, but there are no known instances of a hydraulic press requiring more tonnage.
Selecting press tonnage in the typical pressroom often is little more than guesswork.
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For example, if a job is successful on a 100-ton mechanical press, tonnage tends to stay the same for the life of that job. The job may never have been tried at 75 or 50 tons. With a hydraulic press, however, you can adjust tonnage quickly and easily, tuning the press to precisely the right tonnage for each specific job.
How the Press Affects the Job. In most cases, the effect of stroke is the same on both hydraulic and mechanical presses. However, drop hammers and some mechanical presses seem to do a better job on soft jewelry pieces and impact jobs. The coining action seems sharper if the impact is there.
In deep drawing, however, the full power stroke of a hydraulic press produces significantly better results.
Automation Considerations
There are many ways and reasons to automate a hydraulic press, from simple to the very complex. Because press functionality is at the core of automation, it is advantageous to partner with a press manufacturer that is also an authorized system integrator and has a long history of providing integrated press automation systems for a range of applications.
Automation may be integrated during an initial press installation, or it can be added to an existing press setup. For the latter, most of the time automation is added not because the press is running slowly, but as a result of many other factors, some of them surprising:
- Parts demand has increased beyond the capacity or capability of manual labor to keep up.
- Personnel resources in the geographic area are not adequate or available.
- Press operators are required in other areas of the facility.
- Its more cost-effective to automate an underutilized press than to purchase another new or used press.
- More consistent product quality and quantity are needed.
- Parts may have sharp edges, be high in temperature, be delicate, or are difficult to handle.
The challenge is to identify the right size for the automation system to address production needs for today and the future, while keeping within the project budget. As such, tailoring automation offerings to fit a range of applications is important. This includes everything from basic press automation (such as electrically integrating a material feeder to the press) to large multipress, multirobot autonomous working cells.
34 Important Points About Hydraulic Presses
Hydraulic presses are highly important and find extensive applications across various industries due to their ability to generate and control immense force through the use of hydraulic fluid.
hydraulic presses are crucial tools in manufacturing and various other industries due to their unmatched force generation, precision, and versatility. Their applications range from shaping metals and plastics to producing composite materials, forging strong components, and even impacting areas such as woodworking and healthcare. Their importance in modern industrial processes is undeniable.
Basic Components of a Hydraulic Press
Hydraulic presses are powerful machines that leverage the principles of fluid dynamics to generate substantial force for a wide range of industrial applications. Whether its shaping metal, molding plastics, or compressing materials, hydraulic presses are indispensable tools in manufacturing processes. To understand how these machines work, its essential to delve into their basic components. In this article, well explore the fundamental components of a hydraulic press and how they come together to perform a multitude of tasks.
Hydraulic System
At the heart of every hydraulic press is the hydraulic system, which consists of several key components working together to transmit force efficiently.
1. Hydraulic Fluid
Hydraulic fluid, often a specialized oil, serves as the medium that transfers force within the system. It is chosen for its ability to handle high pressure, lubricate moving parts, and resist temperature variations. Hydraulic fluid is a vital element that ensures the smooth operation of the press.
2. Hydraulic Pump
The hydraulic pump is responsible for generating the primary force within the hydraulic system. It draws in hydraulic fluid from a reservoir and pressurizes it, creating a flow of high-pressure fluid. This pressurization is what ultimately provides the force needed for various operations.
3. Hydraulic Cylinders
Hydraulic cylinders are the workhorses of the hydraulic press. These devices consist of a piston and a cylinder and are where the pressurized hydraulic fluid generates force. When pressurized fluid enters the cylinder, it pushes the piston, producing a linear force that is transmitted to the working tool or die. The size and number of cylinders can vary depending on the presss design and intended applications.
Frame and Structure
The frame and structure of a hydraulic press provide the necessary stability and support for the hydraulic components and the work being performed. Different types of hydraulic presses, such as C-frame, H-frame, or four-column designs, have distinct frames that suit specific applications.
4. Frame
The frame is the outer structure that encases the hydraulic components. It must be rigid and sturdy to withstand the forces generated during operations. Frames are typically made from high-strength materials like steel to ensure durability.
5. Platens
Platens are flat, parallel plates mounted on hydraulic cylinders. They serve as the surface against which the workpiece is placed. The size and shape of the platens can be customized to accommodate various workpiece sizes and shapes.
Control Systems
Control systems in hydraulic presses play a pivotal role in managing the machines operation. They enable precise control over the force applied, speed, and timing of the hydraulic press.
6. Manual Controls
Manual control systems typically involve levers, buttons, or knobs that allow operators to regulate the presss actions manually. While they offer direct control, they may lack the precision and repeatability of automated systems.
7. Automated Controls
Automated control systems use advanced technology, such as programmable logic controllers (PLCs) and human-machine interfaces (HMIs), to automate and fine-tune the presss operations. This automation enhances precision, repeatability, and productivity while reducing the risk of operator error.
Safety Features
Safety is a paramount concern when working with hydraulic presses due to the immense forces involved. Hydraulic presses incorporate various safety features to protect both operators and equipment.
8. Pressure Relief Valves
Pressure relief valves are critical safety components that prevent the hydraulic system from exceeding its designed pressure limits. They release excess pressure, preventing damage or catastrophic failures.
9. Emergency Stop Controls
Emergency stop controls provide a quick and easily accessible means to shut down the press in case of emergencies or when a hazardous situation arises.
10. Safety Interlocks
Safety interlocks ensure that the press operates only when all safety conditions are met. For example, the press may not activate unless safety guards are in place, or operators are at a safe distance.
In conclusion, the basic components of a hydraulic press work together seamlessly to harness the power of hydraulic fluid and produce immense force for various industrial applications. Understanding these components is essential for efficient operation, maintenance, and safety when working with hydraulic presses. Whether shaping metals, molding plastics, or compressing materials, these machines continue to be indispensable tools in the world of manufacturing.
How Hydraulic Presses Works
Hydraulic presses are marvels of engineering that harness the power of fluid dynamics to exert immense force for various industrial applications. Whether its shaping metals, molding plastics, or compressing materials, hydraulic presses play a vital role in modern manufacturing. In this article, well delve into the inner workings of a hydraulic press to understand how it operates and why its a crucial tool in numerous industries.
The Principle of Pascals Law
At the core of a hydraulic presss operation is Pascals law, named after the French mathematician Blaise Pascal. This fundamental law of fluid mechanics states that when pressure is applied to a confined fluid at any point, it is transmitted undiminished throughout the fluid in all directions. In practical terms, this means that if you apply force to a small piston in a hydraulic system, it will generate a larger force on a larger piston connected to it.
Step-by-Step Operation of a Hydraulic Press
To comprehend how a hydraulic press works, lets break down its operation into distinct steps:
1. Hydraulic Fluid Reservoir
The process begins with a hydraulic fluid reservoir, typically filled with specialized hydraulic oil. This reservoir ensures a constant supply of fluid for the presss operation.
2. Hydraulic Pump
A hydraulic pump, often powered by an electric motor or an internal combustion engine, draws hydraulic fluid from the reservoir. It pressurizes this fluid to create a flow of high-pressure hydraulic fluid.
3. Distribution of Pressure
The pressurized hydraulic fluid is then directed to one or more hydraulic cylinders within the press. These cylinders contain pistons that can move back and forth.
4. Application of Force
When hydraulic fluid enters a cylinder, it pushes against the piston inside. The pressure applied on this piston generates a force. According to Pascals law, this force is transmitted evenly throughout the hydraulic fluid and directed toward the working end of the cylinder.
5. Workpiece Contact
The force generated by the hydraulic cylinder is transferred to a platen or working tool. This platen or tool comes into contact with the workpiece to perform the desired operation, such as bending metal, molding plastic, or compressing material.
6. Force Multiplication
One of the most remarkable aspects of hydraulic presses is their ability to multiply force. Because the pressure within the hydraulic system remains constant, a small piston area can generate a much larger force when applied to a larger piston area. This force multiplication is why hydraulic presses are capable of exerting such tremendous pressure.
7. Precise Control
Hydraulic presses offer precise control over the application of force. By regulating the flow of hydraulic fluid, the operator can control the speed and intensity of the presss action, ensuring accurate and repeatable results.
Force Multiplication and Pressure Distribution
To illustrate the concept of force multiplication further, consider a hydraulic press with a small piston area of 1 square inch and a large piston area of 100 square inches. If a 10-pound force is applied to the small piston, it will generate a force of 1,000 pounds (10 pounds multiplied by 100) on the larger piston. This substantial force multiplication capability is what makes hydraulic presses indispensable in tasks that require immense pressure.
Additionally, hydraulic systems distribute pressure uniformly throughout the hydraulic fluid, ensuring that the force is evenly applied to the workpiece. This results in consistent and precise outcomes, critical in industries where accuracy is paramount.
In conclusion, hydraulic presses operate on the fundamental principles of Pascals law, utilizing hydraulic fluid to transmit and multiply force. By understanding the mechanics behind a hydraulic press, we can appreciate how it performs a wide range of industrial tasks with precision and power. From shaping metals to molding plastics, hydraulic presses continue to be essential tools in manufacturing, exemplifying the ingenious application of fluid dynamics in the world of engineering.
Applications of Hydraulic Presses
Hydraulic presses are veritable workhorses of the industry, harnessing the power of pressurized fluid to perform an array of tasks that require precision, force, and versatility. These remarkable machines have revolutionized manufacturing processes across various sectors, from automotive to aerospace, and from construction to healthcare. In this article, well explore the diverse applications of hydraulic presses and their critical role in shaping modern production.
Automotive Industry
1. Metal Forming: Hydraulic presses are integral in automotive manufacturing for shaping various sheet metal components, including car body panels, fenders, hoods, and doors. The ability to precisely form metal parts ensures uniformity and structural integrity in vehicles.
2. Brake and Clutch Systems: Hydraulic presses are used to manufacture brake pads, brake rotors, and clutch plates. The consistent pressure applied during these processes ensures the safety and reliability of automotive braking systems.
3. Suspension Components: Hydraulic presses play a vital role in shaping suspension components, such as control arms, which are critical for ride comfort and vehicle stability.
Metalworking Industry
4. Stamping and Punching: Hydraulic presses are employed for stamping and punching operations in the metalworking industry. They create intricate patterns, holes, and shapes in metal sheets used in a wide range of products, including appliances, electronics, and industrial machinery.
5. Deep Drawing: In deep drawing processes, hydraulic presses are used to form metal sheets into deep, three-dimensional shapes, such as pots, pans, and automotive parts like fuel tanks.
6. Coining: Coining presses, a specialized type of hydraulic press, are used for precision coin minting. They create highly detailed coin designs with consistent quality.
Aerospace Industry
7. Aircraft Component Manufacturing: Hydraulic presses are vital for shaping aircraft components, including wing ribs, fuselage sections, and engine parts. The precision and force they provide ensure the structural integrity and safety of aircraft.
8. Composite Material Processing: In aerospace and other industries, hydraulic presses are used to fabricate composite materials like carbon fiber-reinforced plastics (CFRP). These materials are lightweight yet incredibly strong, making them ideal for aircraft construction.
Construction and Civil Engineering
9. Metal Bending and Straightening: Hydraulic presses are used to bend and straighten metal beams and other structural components used in construction. They play a crucial role in ensuring the structural integrity of buildings and bridges.
10. Concrete and Asphalt Compaction: Hydraulic presses are utilized to compact concrete and asphalt during road construction. This ensures that these materials are dense and stable, extending the lifespan of roadways.
Plastic and Rubber Industries
11. Injection Molding: Hydraulic presses are employed in injection molding processes to shape plastic parts used in countless products, from toys and packaging materials to automotive components and medical devices.
12. Rubber Molding: For the production of rubber components like tires, gaskets, and seals, hydraulic presses are essential. They ensure that rubber materials are accurately molded to meet performance and safety standards.
Art and Crafts
13. Jewelry Making: Artisans and jewelers use hydraulic presses for delicate tasks like embossing, die-cutting, and shaping precious metals and gemstones, allowing for intricate and custom designs.
14. Sculpture Creation: Sculptors often utilize hydraulic presses to manipulate metal or other materials into sculptural forms, making it easier to create intricate and visually striking artworks.
Healthcare Industry
15. Medical Device Manufacturing: Hydraulic presses are employed in the production of medical devices and equipment, including syringes, dental instruments, and prosthetic components.
16. Pharmaceutical Tablet Compression: In pharmaceutical manufacturing, hydraulic presses are used for tablet compression, ensuring consistent and precise doses of medications.
Environmental Initiatives
17. Recycling: Hydraulic presses compact recyclable materials like paper, cardboard, plastics, and metals, reducing their volume for easier transport and recycling. This aids in environmental conservation by reducing landfill waste.
In conclusion, the applications of hydraulic presses are as diverse as the industries they serve. Their ability to generate precise and powerful forces through the manipulation of hydraulic fluid has revolutionized manufacturing processes worldwide. From shaping metals and plastics to forging aerospace components and even creating intricate sculptures, hydraulic presses continue to be indispensable tools that underpin modern industry and innovation.
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