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Cockcroft-Latham Fracture Criterion and Bulk Formability

of Copper Base Alloys


Cockroft-Lathamov kriterij loma in masivna preoblikovalnost
bakrovih zlitin
B. Ule*, V. Leskovek, B. Breskvar, Institute of Metals and Technology, Ljubljana,
Slovenia
K. Kuzman, D. vetak, Faculty for Mechanical Engineering, Ljubljana, Slovenia
F. Kofol, Kolektor, Idrija, Slovenia

The ductility of metalic materials is generally defined as the ability to deform plastically vvithout
fracture. It is usually expressed as a measure of the strain at fracture in a simple tension test1.
Hovvever, the percentage elongation in a tensile test is often dominated by the uniform
elongation, vvhich is dependent on the slope of the stress/strain curve. The end of uniform
elongation coincides vvith the onset of plastic instability accompanied by voids nucleation, their
grovvth and coalescence. It appears that the elongation value is too complex to be regarded as
a fundamental property of a material and it seems reasonable to assume that any criterion of
fracture vvill be based on some combination of stress and strain rather than on either of these
quantities separately. Tvvo grades of copper base alloys used for the production of commutators
for electrical motors vvere tested in compressing and stretching. The bulk formability of these
alloys vvere projected using the Cockcroft-Latham criterion23, based on the tensile strain energy
density at fracture. This criterion emphasizes the importance of tensile stresses in fracture and
can be applied to a variety of cold vvorking processes.
Key vvords: ductility, formability, fracture, Cockcroft-Latham fracture criterion, copper base alloys

Duktilnost kovinskih materialov je v splonem definirana kot sposobnost, da se plastino


deformirajo brez pojavljanja razpok. Obiajno jo izrazimo z lomno deformacijo pri enostavnem
nateznem preiskusu1. I/ odstotkih izmerjen celokupni raztezek pri nateznem preiskusu je dokaj
odvisen od enakomernega raztezka, to je od strmine krivulje napetost-deformacija. Konec
enakomernega raztezanja sovpada s pojavljanjem plastine nestabilnosti, ki jo spremlja
nastajanje por, njihova rast in zdruevanje. Zdi se, da je raztezek preve kompleksen in ga ne
moremo smatrati kot osnovno materialno lastnost. Zato je smiseln privzetek, po katerem bo
moral lomni kriterij temeljiti prej na neki kombinaciji napetosti in deformacij, kot le na eni
posamini koliini. Za tlano in natezno preiskuanje smo izbrali dve bakrovi zlitini za izdelavo
kolektorjev pri elektromotorjih. Masivno preoblikovalnost teh zlitin smo opredelili s Cockcroft-
Lathamovim kriterijem23, ki temelji na gostoti natezne deformacijske energije. Ta kriterij poudarja
pomen nateznih napetosti pri lomu in ga lahko uporabitmo pri razlinih procesih preoblikovanja
v hladnem.
Kljune besede: duktilnost, preoblikovalnost. lom, Cockcroft-Lathamov kriterij loma, bakrove
zlitine.

1. Introduction reductions could bc achieved in ductile materials, and that even


The evolution of ductile damage within the d e f o r m i n g body some brittle materials could be extruded vvithout difficulty. In a
is considerably influenced bv the stress state in the material. It tensile test of a eylindrical test specimen the stresses at the min-
was suggested bv Siebel 4 that the cracking in metalworking is as- imum section of the neck can be calculated in different vvavs" 1
sociated with induced tensile stresses. even in processes such as and may be considered to be the sum of tvvo parts. One part. the
forging that are predominantly compressive. The importance of equivalent stress. is equal to the current yield stress and is con-
tensile stresses is indirectly confirmed by the large inerease in stant aeross the cross-section. The other part, a hydrostatic ten-
ductilitv vvhen the materials are deformed under hydrostatic sion, varies from zero at the periphery to a peak value at the
pressure 1 . Pugh and Green'' demonstrated that superimposing a centerline. As stated by Cockcroft and Latham '. that the use of
hydrostatic pressure in the extrusion process greatly enhanced the criterion based on total plastic vvork per unit volume at the
fracture point, vvhich vvould take into account only the equiva-
* Dr. Boris ULE. dipl. in.,
IM'I Ljubljana. Lepi pol 1 1, 61000 Ljubljana lent stress i.e. the current yicld stress, is not a proper solution.
T h e current y i c ki slrcss, unlike the pcak stress, is not intluenced factor representing the effect of the highest tensile stress. cr*.
by the shape of the neeked region. C o n s e q u e n t l y , the neck shape and C is a material constant. If there is no tensile stress
should have no effect 011 the fracture strain. a conclusion which operating but only a c o m p r e s s i v e stress. it* = 0 and fracture
is eontrary 10 cxperimental facts'. T h e r c f o r e C o c k c r o f t ' and docs not occur'.
C o c k c r o f t and Latliam 1 proposed a criterion based 011 the tensile T h e expression (1) has the d i m e n s i o n s of vvork per unit vol-
strain energv densitv w h e r c the m a g n i t u d e of the highest normal u m e ( N / n r = N m / m ' = J/m 1 ). T h e reduced form
stress is taken into account. At tensile testing this would bc the
stress aeting in the ccnterline w h e r e fracture is initiated.
a ile = C .2)
As an o u t g r o w t h of experimental e v i d e n c e of the influence
of stress stale on duetile fracture, several other eriteria vvere also
is used for calculation. T h e correction for neeking and pro-
suggcsled for the predietion of fracture in c o m p l e x stress states.
jections for .1 could bc obtained bv d i f f e r e n t approaches
A modilication of the C o c k c r o f t - L a t h a m criterion vvhich in-
Wright and coworkers I H . for instance, s u c c e s s f u l v used the e q u a -
cludcs a hydrostatic-prcssure term vvas suggested bv B r o / o et
tions of D a v i d e n k o v and S p i r i d o n o v a . vvhereas the equations of
al. 1 . O t h e r eriteria of i m p o r t a n c e vverc proposed bv O y a n e
B r i d g m a i r vvere used in our experiments.
Clift 1 1 H o f f m a n n e r 1 ' and O s a k a d a " ' . Sueh eriteria vvere success-
lullv applicd bv a n u m b e r of investigators to a varietv of eold Fig. 1 illustrates the g e o m e t r v at the neeked region and the
vvorking operations 1 '. distribution of axial stress bv this localized d e f o r m a t i o n . I11 ae-
c o r d a n c e to B r i d g m a n \ the variation of the stresses in a mini-
m u m scction of a neeked bar in tension is given as
2. F r a c t u r e criterion
= ct(i + 2 p/R) In (\ + R / 2 p ) (3a)
W i t h the C o c k c r o f t and Latliam tensile ductility a p p r o a c h ,
the fracture is predieted vvlien
R:+ 2Rp - ; (3b)
<T, = <7 = a In
2 Rp
J ( 7 (o" / a ) d f = C ( 1 )

a o + cs (3c)

vvherc t' is equivalent i.e. e f f e c t i v e strain, , is cquivalcnt strain vvhere (r. is the a v e r a g e stress on the m i n i m u m scction of
al fracture, cr is cquivalent i.e. e f f e c t i v e stress, o is the highest the n e c k (load d i v i d e d bv m i n i m u m n e c k area). R is the radius
tensile stress, (it*/i~t) is a n o n - d i m c n s i o n a l stress-conccntration of the m i n i m u m c r o s s scction at the n e c k , r' is the so called
" s t r a i n e d l e n g t h " ( r ' = r R/R), R,, is the radius of initial cross
scction (R = 5 m m ) and p is the radius of c u r v a t u r e of the neck
Load profile. In the ccnterline of the n e e k e d r e g i o n , vvhere r = r' = 0.
z = 0 the stress c o m p o n e n t it,, r e a c h e s the highest value
ir = <r

- - , R + 2p
a = <7 + o In (4)

C o n s i d e r i n g the strain h a r d e n i n g . the llovv c u r v e can bc ap-


proximated by several constitutive equations. T h e most c o m m o n
are proposed by H o l l o m o n " , Ludvv ik" . Svvift 24 and V o c c . T h e
most simple one is (lic H o l l o m o n povver lovv relation:

a = KI" (5)
vvhere 11 is the strain-hardening e x p o n e n t and K is the
strength c o e f f i c i e n t of the material. Both constants c o u l d bc
d e t e r m i n e d simply bv the values of 0.2'v offset yield strength
and fracture stress l s or bv c o m p u t e r least-squares fits by plotting
hi o against hi i . vvhere 11 and K are the slope and intercept
respectivcly. Hovvever, the strain-hardening e x p o n e n t n. and the
strength c o e f f i c i e n t , K. could bc also evaluated front the tensile
test dala bv applving the criterion of instabilitv at the onset of
neeking. d a / d e = it. F r o m this. it can bc shovvn that at neeking.
vvhere the ultimate tensile strength is m e a s u r e d . the strain-hard-
ening exponent is given as

f = 11 (M
O n c e the strain-hardening c x p o n e n t is knovvn. the strength
c o e f f i c i e n t K in the Eq. (31 can be eusilv d e t e r m i n e d bv m e a n s of
ultimate tensile strenath a u , as

Load \n
K = cr uls (2 7 1 S 2 8 / n ) (7)
Figure I: The geomelry al the neeked region and the distribution
of axial stress <r.
Slika I: Geometrija vratu in porazdelitev aksialne From the results of Eq. (5), a relationship of it 10 t' can be
napetosti it,,. d e t e r m i n e d bv using Eqs. (3a) and (4) and a s s u m i n g that the
necking is initiated at the ultimate tensile strength o\ lls w h e n 3. E x p e r i m e n t a l m e t h o d s
ti",, = <r and vvhen E achieves n (Hq. 6). a s s u m i n g also that cr
Tvvo c o p p e r base alloys declared as CuAg().2 (OF) and
increases linearlv vv ith equivalent strain (Fig.2). C o n s i d e r i n g the
C u A 0 . 2 respectivelv vvere selected for the present study. Both
hatched areas on Fig. 2. the integral (2) can be separated as
follovv s allovs, c o m m e r c i a l l y available as one-half inch d i a m e t e r vvires,
contain 0.2 vvt. 7< Ag. This type of c o p p e r base allov s has good
creep strength at elevated t e m p e r a t u r e s and high s o f t e n i n g tem-
C = J<7 de = J rr de + | a de (S) perature and is used for instance for the production of c o m m u t a -
tors for electrical motors.
B> substituting the knovvn f u n c t i o n <r r.v. t' and using a Irape- T h e cxperimental CuAg().2 allov contained 0.01 vvt. 7c O and
zoidal f o r m u l a for the second integral, vve finallv get 0.005 vvt. 7, P vvhereas the CuAg().2 (OF) alloy i.e. o x y g e n f r e e
allov contained < 0.005 vvt. 7, O and 0 . 0 0 2 vvt. 7, P. Hovvever,
r * i, r the bulk vvorkabilitv of CuAg().2 allov vvith higher o x y g e n con-
(9)
/1+1 " tent vvas essentiall) wor.se than that of o x y g e n free allov. As
s h o w n on Fig. 3, a duetile d a m a g e occured at eold b e n d i n g of
c o m m u t a t o r s e g m e n t s f r o m such o x y g e n containing CuAg().2 al-
lov. O n the contrary, the bulk formability of experimental o x y -
gen free alloy was excellent as it d i d r f t present any p r o b l e m s in
Of
metal vvorking processes.
0*
T h e microstructure of both allovs is shown in Fig. 4 and 5.
Of
/ ' , T h e microstructure of o x y g e n containing CuAg().2 allov (Fig. 4)
o vs e consisled of relatively small grains with tvvinned areas. vvhereas
/ / / / / / / / / the microstructure of o x y g e n free C u A g 0 . 2 alloy (<0.005 7< O)
(Fig. 5) is characterized by s o m e w h a t larger. equiaxed grains

V-i*-

Ey E,
True Strain
Figure 2: Effective stress. a. and peak stress. a , versus effective
strain at tensile testing (schematically).
Slika*2: Ekvivalentna napetost o in maksimalna napetost o
r S**;
v odvisnosti od ekv ivalentne deformacije pri natezanju (shematsko).
./j -rmg^f-..

50jjm
h H
Figure 4: Microstructure of oxygen containing CuAg0.2 allov . shovv ing
relatively small grains vvith some tvvinned areas.
Slika 4: Mikrostruktura kisik vsebujoe zlitine CuAg0.2. Razmeroma
drobna kristalna zrna s posameznimi podroji dvojeenja.

Figure 5: Microstructure of oxygen free CuAg().2 allov. shovv ing


equiaxed grains vvith irregular boundaries. Some grains contain
Figure 3: Cracks on commutator segments occured at eold bending. tvvinned areas.
Slika 3: Razpoke, nastale na krakih kolektorja pri upogibanju v Slika 5: Mikrostruktura kisika proste zlitine CuAg0.2. Enakoosna
hladnem. kristalna zrna z iregularnimi mejami in dvojki v posameznih zrnih.
with irregular b o u n d a r i e s and t w i n n e d areas. T h e m i c r o s t r u c t u r e T a b l e I: Tensile test results
of both alloys is typical for the as a n n e a l e d state w h e r e only a T a b e l a I: Rezultati n a t e / n e g a p r e i z k u a n j a
slight cold reduction w a s applied at the calibration d r a w i n g .
Tensile flovv curves w e r e obtained using an Instron m a c h i n e Vield Tensile Uniform Total Reduction
stress' strength elongation elongation in area
by pulling standard tensile s p e c i m e n s vvith g a u g e sections of Z \ 11)1)
<r e u x 100 e,n X 111(1
ul,
10 m m d i a m e t e r and 100 m m length at a c r o s s - h e a d speed of (MPa) (MPa) (%) (<7r) (%)
1 m m / m i n . T h e neck profile radius vvas established f r o m the
p h o t o g r a p h s of the necked region using an appropriate g e o m e t - CuAg0.2 allov 306 323 -> 9 68
rical a p r o x i m a t i o n . A d i s c o n t i n u o u s c o m p r e s s i o n testing vvas (0.01 O) (321)
carried out on a instrumented hydraulic press on s p e c i m e n s vvith
CuAg0.2 (OF) 2^2 258 142 27 87
10 m m in d i a m e t e r and initial height of 12 m m . In order to m i n - r
allov(<0.005 i O) (248)
imize the frictional constraints, teflon vvas used on contact
surfaces and constant frietion c o e f f i c i e n t of 0 . 0 2 4 vvas a c h i e v e d . * The values in parenthesis vvere obtained by compression testing
C u m u l a t i v e height reductions reached 86 %. T h e strain rate at
c o m p r e s s i o n testing vvas c o m p a r a b l e vvith that at the u n i f o r m
tension and r e m a i n e d nearlv constant over most of the strain T a b l e II: C o m p a r i s o n of H o l l o m o n eonstants bv various test
range. L o a d - d i s p l a c e m e n t data obtained vvere fed into a c o m - methods
puter by points for stress-strain analysis. A correction factor for T a b e l a II: P r i m e r j a v a H o l l o m o n o v i h konstant d o b l j e n i h pri ra-
the a d e q u a t e c o m p e n s a t i o n of frietion vvas also incorporated into zlinih m e t o d a h p r e i z k u a n j a
the e o m p u t e r program.
Strength Strain-hardening Correlation
coefficient e.iponent coefficient
4. Results K n r
(MPa)
Fig. 6 are the plots of load vs. elongation at tensile test of
both e x p e r i m e n t a l alloys. T h e values obtained at testing are Compression Test
listed in T a b l e I. T h e yield stress at tensile testing vvas deter-
CuAg0.2 allov 397 0.090 0.977
mined as 0.2 'h O f f s e t Yield Stress. T h e yield stress m e a s u r e d at
(0.01 'i O)
c o m p r e s s i o n testing is also included in the table (values in paren-
thesis). As alreadv m e n t i o n e d , the radius of the m i n i m u m cross CuAg0.2 (OF) allovir 379 0.139 0.993
seetion of the neck R. and the radius of curvature of the neck 0.005 <k O)
profile r. of the tensile s p e c i m e n s vvere m e a s u r e d too. By the
Tension test
C u A g 0 . 2 alloy (0.01 % O) the neck profile radius vvas 2.20 m m .
the m i n i m u m cross seetion radius vvas 2.85 m m , vvhereas at CuAg0.2 allov 431 0.087
o x y g e n free C u A g 0 . 2 alloy (<0.005 '/i O), vvhere m o r e a rupture (O.of% Oi
than a fracture vvas o b s e r v e d , the neck profile radius vvas only
CuAg0.2 (OF) alloy 385 0.133
0.15 m m and the m i n i m u m cross seetion radius vvas 1.8(1 m m .
0.005 O)
In T a b l e II the values of H o l l o m o n e o n s t a n t s calculated
Calculated from the true stress-true strain tensile test data
f r o m the c o m p r e s s i o n - and tensile lests data are listed. T h e eon-
"Calculated from the uniform elongation /Eq. (6)/
stants. obtained f r o m tensile test data vvere d e t e r m i n e d bv vari-
ous m e t h o d s of analysis, because the high percent error in u
m a k e s s o m e t i m e s the Eq. (6) u n a c c e p t a b l e . Hovvever, n is the
T a b l e III: Values of the material eonstants
e x p o n e n t of an empirical equation (5) and it is not surprising that
this equation cannot accurately deseribe the stress-strain c u r v e s T a b e l a III: Vrednosti materialnih konstant
in the vvhole strain range. Man et al.-" deseribed the tensile curves
CT u eu o e, (T , C/Eq(9)/
(MPa) (MPa) (MPa) (MPa) (MJ/m1)

CuAg0.2 allov 306 330 0.019 435 1.124 652 548


(0.01 % O)

CuAgO,2(OF)
allov 212 288 0.129 423 2.041) 124d 1499
0.005 % 0 )

of c o p p e r using tvvo equations of H o l l o m o n tv p e " . This kind of


analysis is based on the a s s u m p t i o n that a c h a n g e in d e f o r m a t i o n
m e c h a n i s m occurs during the d e f o r m a t i o n .
T h e collection of final results is given in T a b l e III vvhere
0.2 /( offset yield stress. a . a v e r a g e ultimate stress. <r,, . and
f r a c t u r e stress. <rr, vvith c o r r e s p o n d i n g strains, f and 8, respec-
tively, the highest tensile stress <r as vvell as the m a t e r i a l con-
Figure 6: Load vs. elongation at tensile lest of both experimental
allovs. stant C are shovvn. T h e value of C, i.e. the value of tensile strain
Slika 6: Odvisnost med obremenitvijo in ra/.tezkom pri nate/nem e n e r g y density of o x y g e n free C u A g 0 . 2 allov (<0.005 c< O) is
preiskuanju obeh eksperimentalnih /litin. extremely large. This allov vvith lovv o x y g e n content exhibited
more a rupture than a fracture at tensile testing resulting in to a stabilizing effect and an inerease in ductility causes a deep-
adequate small radius of curvature o f t h e neck profile while the er neck to be formed, hence higher local stresses are developed
tensile stress in necked region strongly increased. In spite o f t h e and a greater possibility of fracture occurs. The Cockcroft-
fact that the original Bridgman 5 analysis and the similar analysis Latham criterion of duetile fracture is therefore a much more
of Davidenkov and Spiridonova 7 give the best approximate reasonable criterion than the criterion based simply on reduction-
procedure for the calculation of stress distribution in the necked in-area value at tensile test. Hovvever. it should be noticed that at
region, novvadavs, more accurate numerieal solutions can be the neck profile vvhich is characteristic for rupture instead of
obtained with FEM. fracture, the extremely high value of tensile stress <r . and high
tensile strain energy density C. are somevvhat doubtful. The
equations of Bridgman 5 /(3a,b and c) and (4)/ and equations of
5. Discussion
Davidenkov and Spiridonova becomes questionable at very lovv
Using the fracture criterion based on the model of Cockcroft radius of curvature of the neck profile typical for the rupture and
and L a t h a n r '. the tensile strain energy density at fracture f o r t w o vvhen asymptotic continuum mechanics analyses could not be
copper base allovs was calculated. The calculation utilized the applied for the deseription of stress state due to local singularitv.
results of tensile and compression tests. When the constant cross-
The excellent bulk formability o f t h e experimental CuAg().2
head-speed is used at tensile test, the strain rate decreases slighty
oxygen free alloy vvith regard to the verification based on the
during the homogenous deformation and then rises rapidly as
Cockcroft-Latham criterion is not surprising. This criterion has
neeking occurs. The rise in strain rate during the neeking results
the desirable feature for homogenous compression, in vvhich ase
in an anomalous rise in flow stress and restriets the usefulness of
the tensile stress o ' is zero and no fracture limit is predieted. This
the data obtained by strains smaller than those prevailing during
coincides vvell vvith the experimental results at homogeneous
the onset o f t h e neeking 2 7 . Probably some discrepancies betwccn
(frictionless) compression. Hovvever, follovving the theoretical
the tensile and the compression test results (see Table II) could
analysis of Kuhn et al. 1 , it is possible to relate the C-value calcu-
be explained also vvith Bauschinger effect and vvith the assump-
lated from tensile test data /Eq. (9)/ and the principal tensile and
tion that a change in deformation mechanism occurs during
compressive surface strains, i.e. the circumferencial and axial
tensile deformation. Zanki 2 * and Schvvink and Vorbrugg 2 " found
strains measured on the barreled equatorial free surface at fracture
ihesc kind of stages also in the tensile curves of annealed nickel
in upset lest. It vvas also experimentally confirmed that there is a
and copper at lovv strains. Furthermore. Mishra at al. 1 " proposed
linear relationship betvveen the tensile and compressive surface
that in the range of uniform strain the Hollomon lavv overesti-
strains at fracture by upsctting by rolling and by bending.
mates the flovv stress in the initial stages and underestimates it in
Consequently, the representation of fracture data as a plot of ten-
the final stages. It seems therefore, that the tensile test data of
sile versus compressive strains at fracture became a useful form
experimental copper base allovs should fit better vvith double-n
for the analysis o f t h e fracture in eold forming processes resulting
method vvhich uses the tvvo Hollomon equations. Kleemola and
in a "forming limit diagram concept". The Cockcroft-Latham ten-
Nieminen- 1 found out that the use o f t h e Hollomon equation for
sile strain energy fracture criterion is consistent vvith this concept'.
pure copper in an annealed state and after 40 pet deformation
gives a misleading pieture of the strain-hardening properties of
the material because the strain-hardening exponent n is not equal 6. Conclusions
to the correct e u value. The same vvas also observed in our
The Cockcroft-Latham tensile strain energy density criterion
CuAg0.2 experimental alloy vvith 0.01 % oxygen vvhere
vvas used for a reliable evaluation of the ability of tvvo copper
computer least-squares fits by plotting tensile test data had to be
alloys to metalvvorking operations. This criterion implies that the
used instead of F.q. (6). In opposition to tensile test data, the
fracture depends both on the stresses imposed and on the strains
compression test data are obtained from a much larger strain
developed and it could be deseribed as "fracture vvill occur vvhen
range and it is therefore assumed that the use of the simple
the plastic vvork of the largest tensile stress, per unit volume,
Hollomon povver lavv relation is justified. The regression analy-
reaches a characteristic critical value".
sis of compression test data also gives satisfactory high linear
correlation coefficients (0.98 and 0.99 respectively). It vvas demonstrated that there is a good qualitative agree-
ment betvveen the predietion of formability under bulk metal-
The data presented in Table l i l (C-values) shovvs that at vvorking conditions based on this criterion and the observed
oxygen free CuAg().2 alloy the integral of the maximal tensile behaviour in the production of commutators forelectical motors.
stress over the plastic strain path /Eq. (9)/ reaches a value of ap- The plastic vvork done per unit volume by oxygen free CuAg().2
prox. 1500 MJ/m". vvhich is ncarl v three times larger than that of alloy vvith excellent bulk formability is nearly three times larg-
CuAg0.2 allov vvith 0.01 % oxygen (C approx. 550 MJ/m 1 ). er than that done by the oxygen containing CuAg0.2 alloy
Hovvever. the reduction in area at tensile test of oxygen free (0.01 % O), vvhile, the difference in the tensile reduction of area
CuAg0.2 allov is only for one quarter larger than that of CuAg0.2 of both alloys vvas much smaller. Consequently, the reduction-
allov vvith 0.01 % oxygen. It seems that a considerable inerease in-area value at tensile test cannot be appreciated in general.
in ductilitv may result bv an on!y relatively lovv improvement in
the reduction-in-area value. so that such way of expressing the References:
duetiIity shovvs little diserimination in very duetile metals.
1
Namely. once the neeking develops, a "negative f e e d b a c k " effect Kuhn, H. A.. Lee, P. W.. Erturk, T.: Trans. ASME, 1973,
occurs. vvhich tends to prevent the exhibition of really large 213-218.
ductilitv values'. At the onset of neeking, the stress system 2
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