engineering design laboratory guide
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A111D3 ^flOSS
U.S. DEPARTMENT OF COMMERCENational Institute of Standards and Technology
NISTIR4519
PUBLICATIONS t
Engineering Design
Laboratory Guide
Allison Barnard Feeney
Factory Automation Systems Division
National Institute of Standards and Technology
Gaithersburg, MD 20899
February 19, 1991
U.S. DEPARTMENT OF COMMERCENational Institute of Standards and Technology
NISTIR4519
Engineering Design
Laboratory Guide
Allison Barnard Feeney
Factory Automation Systems Division
National Institute of Standards and Technology
U.S . DEPARTMENT OF Gaithersburg, MD 20899
COMMERCERobert A. Mosbacher, February 19, 1991
Secretary of Commerce
National Institute of
Standards and Technology
John W. Lyons, Director
Notes
The author would like to acknowledge Peter E Brown and Y. Tina Lee for their assistance
in providing information necessary to complete this document.
This publication was prepared by United States Government Employees as part of their
official duties and is, therefore, a work of the U. S. Government and not subject to copy-
right.
Certain commercial equipment, instruments, or materials are identified in this paper. Such
identification does not imply recommendation or endorsement by the National Institute of
Standards and Technology, nor does it imply that the materials or equipment identified are
necessarily the best available for the purpose.
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Allison Barnard Feeney Table of Contents
Table of
Contents
Introduction 1
Alpha_l 2
COSMOS/M 3
Design History Tool 4
ICAD 5
ModaCAD 6
Newton 7
NextCut 8
N-See 9
Parasolid 10
Supporting Hardware and Software 11
Facility 12
Research Opportunities 13
Engineering Design Lab Guide Page iii
Allison Barnard Feeney Introduction
EngineeringDesignLab
Engineering Design
Laboratory Guide
Allison Barnard Feeney
Factory Automation Systems Division
National Institute of Standards and Technology
Gaithersburg, MD 20899
Introduction
The Engineering Design Laboratory
(EDL) was established by the Factory Au-
tomation Systems Division at the National
Institute of Standards and Technology
(NIST). The EDL was created to study the
process of design, how design information
can be represented, and how to make this
information available to necessary systems
throughout a product’s life cycle. The EDLis a facility equipped with state of the art
computers and software dedicated to these
tasks.
The EDL supports projects funded by
NIST, Defense Advanced Research
Projects Agency (DARPA), Defense Lo-
gistics Agency (DLA), and the Navy. The
goal of the EDL is to develop ways to rep-
resent design knowledge or intent in a man-
ner that is compatible with the emerging
standard for exchange of product model
data, STEP. We are concentrating our ef-
forts in the domain of rigid mechanical
parts, including assemblies. A primary fo-
cus of the EDL has been working with
DARPA to help build a community of re-
searchers who are studying design repre-
sentation.
One of the ways we are pursuing our
goals is by making the EDL available to
other researchers for collaborative or inde-
pendent projects. NIST has a Research As-
sociate Program through which a variety of
arrangements between interested parties
can be formalized.
The following pages contain descrip-
tions of the equipment and software avail-
able in the EDL. This equipment and
software is continually being upgraded and
augmented to reflect the state of the art.
Engineering Design Lab Guide Page 1
Alpha_1 Allison Barnard Feeney
Alpha_l
Alpha_l is non-uniform rational b-
spline (NURB) based geometric modeling
system developed at the University of Utah.
It is available commercially through Engi-
neering Geometry Systems. A goal of the
Alpha_l research has been to advance the
integration of design, modeling, analysis
and manufacturing to shorten and improve
the quality of the overall process. Spline
representations, used exclusively in Al-
pha_l, are necessary for a large class of ob-
jects including turbine blades, airplane
fuselages, injection molded parts, and a
great variety of common as well as unusual
objects with difficult shapes. Alpha_l
models are described by a program or algo-
rithmic procedures in a Lisp-like language.
Changes to the master model are immedi-
ately reflected in the graphics window.
Parametric part designs allow the user to
develop new, high-level primitives to facil-
itate modeling designs with commonly
used forms.
Status:
We will be working with the University
of Utah to model a complex diesel engine in
Alpha_l. In the EDL, Alpha_l is currently
only running on the Silicon Graphics Iris.
With the next release of the software, we
will be running Alpha_l on the Sun 4 plat-
form, only. In general, Alpha_l runs on a
variety of engineering workstations (Sun,
HP, Silicon Graphics, Chromatics, Evans
and Sutherland) and requires University of
Utah’s Portable Standard Lisp and X Win-
dows or a native graphics system. Emacs is
also needed for model editing via the com-
mand interface.
Further Reading:
Alpha 1 User’s Manual , University of
Utah, Salt Lake City, 1988.
Developers:
Elaine Cohen
Rich Riesenfeld
Department of Computer Science
3190 Merrill Engineering Building
University of Utah
Salt Lake City, Utah 84112
(801)581-8224
Worm gears modeled in Alpha_l.
Page 2 Engineering Design Lab Guide
Allison Barnard Feeney COSMOS/M
COSMOS/M
COSMOS/M is a commercially avail-
able finite element analysis package for
general purpose structural analysis. COS-
MOS/M has a CAD-like front end mesh
generator and an IGES interface to and
from CAD systems. The capabilities in-
stalled at the EDL are: mesh generation,
post processing, linear static and dynamic
analysis, frequencies, mode shapes, dy-
namic responses, and heat transfer analysis.
Status:
We are using COSMOS/M for general
structural analysis problems related to the
Molecular Modeling Machine Project at
NIST. We have Version 1.61 installed and
running on the IBM PS/2 and on the Sun 4
workstation. COSMOS/M runs on a vari-
ety of PC platforms. It requires a graphics
card and math co-processor. It also runs on
several engineering workstations (e.g. Mi-
crovax. Sun, HP, Silicon Graphics, Apollo
and ComputerVision).
Further Reading:
Lashkari, M., COSMOS/M User*s Guide
SRAC, Santa Monica, 1989.
Lashkari, M., GEOSTAR User's Guide .
SRAC, Santa Monica, 1989.
Developer:
Structural Research and Analysis Corp.
1661 Lincoln Boulevard Suite 100
Santa Monica, California 90404
(213) 452-2158
Engineering Design Lab Guide Page 3
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Design History Tool Allison Barnard Feeney
Design History
Tool
The Design History Tool is a research
system from Oregon State University for
representing design objects and the changes
encountered as they evolve from abstract
concepts to concrete forms. Design objects
include assemblies, parts of assemblies and
interfaces between assemblies and parts.
All of the objects are described in terms of
context sensitive form and function fea-
tures. The changes that occur to the design
objects are a result of design operators ap-
plied to the existing design information in
the Mechanical Design Database. The rep-
resentation of the changes the objects en-
counter provides a mechanism for
capturing the relationship between con-
straints, design objects and the design pro-
cess that describes the evolution of the
objects from constraints.
Status:
We currently have the design of a bat-
tery housing modeled in the Design History
Tool. The Design History Tool is running
on the Sun 4 workstation in the EDL.
Further Reading:
Ullman, David G., Thomas G. Dietterich,
Mechanical Design Process Research
Group Research Overview . Oregon
State University, Corvalis, Oregon,
1989.
Tikerpuu, Juri, David G. Ullman, General
Feature-Based Frame Representation
for Describing Mechanical Engineering
Design Developed from Empirical
Data, ASME CIE Conference, San
Francisco, July 1988.
Developers:
David G. Ullman
Thomas G. Dietterich
Department of Mechanical Engineering
Oregon State University
Corvalis, Oregon 97331
(503) 737-2336
Page 4 Engineering Design Lab Guide
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Allison Barnard Feeney ICAD
ICAD
The ICAD System™ is an interactive,
knowledge-based software product for me-
chanical design and manufacturing engi-
neering automation. ICAD allows the user
to build a model that describes the engi-
neering, design, and manufacturing pro-
cesses. Changes to input parameters cause
a completely new design to be created auto-
matically. ICAD attempts to capture the
design intent behind the product design.
The product model includes product struc-
ture and part dependencies, physical and
geometric properties, manufacturing cost
constraints, design specifications, decision
criteria for material selection, standard
parts from on-line catalogs, generation of
manufacturing process plans, and access of
information from external databases. From
this model, the user can get a bill of materi-
al, completed detail designs, data for draw-
ings, engineering reports, manufacturing
process plans, numerical control programs,
inputs to MRP systems and cost analyses.
Rules are defined in ICAD Design Lan-
guage™ which is a declarative, ob-
ject-oriented language. Geometry is
defined with a complete set of geo-
metric primitives. Geometry may
also be input from a number of CADsystems.
Status:
ICAD and NIST are participating
in a research agreement to develop
representation schemes for Design
Knowledge. This is being done in
conjunction with part design for the
Molecular Modeling Machine project at
NIST. We have ICAD Version 2. 1 .2 for the
Sun 4 workstation installed and running in
the EDL. Other platforms supported by
ICAD are the Apple Macivory and Silicon
Graphics.
Further Reading:
ICAD User’s Manual , ICAD, Inc., Cam-
bridge, Massachusetts, 1990.
ICAD Surface Designer— User’s Manual ,
ICAD, Inc., Cambridge, Massachusetts,
1990.
Wagner, Martin R., Understanding the
ICAD System™ , ICAD, Inc., Cam-
bridge, Massachusetts, 1990.
Developer:
ICAD, Inc.
1000 Massachusetts Avenue
Cambridge, Massachusetts 02138
(617) 868-2800
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Molecular Modeling Machine part modeled in ICAD.
Engineering Design Lab Guide Page 5
ModaCAD Allison Barnard Feeney
ModaCAD
ModaCAD is an integrated system of
application programs that addresses all as-
pects of apparel design and production. It
is commercially available from ModaCAD,Inc., and runs on the Macintosh n series of
computers. The ModaCAD programs in-
stalled at the EDL include a paint program,
an image processing program, a program
for designing fabric, a program for display-
ing fabric draped on a model (including
lighting effects), a pattern design program
(including grading), a program for generat-
ing pattern markers, a relational database
program for apparel data, and a scheduling
program to produce schedules for apparel
manufacture.
Status:
The ModaCAD system is installed on
the Macintosh IIx computer in the EDL. In-
cluded in the system configuration is an op-
tical disk system containing an apparel
library of pictures, a color printer and color
scanner. We are studying this system as an
example of an apparel CAD/CAM system
to help us in developing an information
model for data required in the apparel in-
dustry.
Further Reading:
Each program in the ModaCAD system
includes a user’s manual, available from
ModaCAD, Inc.
Developer:
ModaCAD, Inc.
1954 Corner Avenue
Los Angeles, CA 90025
(213)312-6632
ModaCAD simulation of the finished garment on a
live model.
Page 6 Engineering Design Lab Guide
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Allison Barnard Feeney Newton
Newton
Newton is a research system developed
at Cornell and Purdue Universities. New-
ton is a dynamic simulation system that
simulates and analyzes systems of physical
objects. The user specifies the shape, mate-
rial composition, and the mechanical inter-
relationships of the objects. From this
description the system constructs a variety
of models, sometimes guided by additional
user specifications, where each model cap-
tures the object behavior in a specific phys-
ical domain. Newton deals with the
behavior of rigid bodies that can be hinged
and interrelated in a number of ways. Giv-
en the description of shape and material
composition, a set of motion equations is
formulated automatically that expresses the
dynamic behavior of the objects in Newto-
nian mechanics.
Status:
We will be using Newton to verify de-
sign criteria of the Molecular Modeling
Machine project here at NIST. The current
version of Newton has been installed and is
running on the Sun 4 workstation. Newton
requires Lucid Common Lisp and X Win-
dows. CLX is needed if graphical output is
desired. In addition, Newton runs on other
engineering workstations including Silicon
Graphics, Symbolics, and DEC.
Further Reading:
Cremer, Jim, An Architecture for General
Purpose Physical System Simulation-
Integrating Geometry, Dynamics and
Control . Cornell University, Ithaca,
1989.
Developers:
John Hopcroft
Department of Computer Science
41SOB Upson Hall
Cornell University
Ithaca, New York 14853
(607) 255-7416
Christoph Hoffman
Department of Computer Science
Purdue University
West Lafayette, Indiana 47907
(317) 494-6010
This is a Newton-generated image showing the
physical reactions of a post and a multi-bar linkage
assembly a few frames after the linkage has hit the
post.
Engineering Design Lab Guide Page 7
NextCut Allison Barnard Feeney
NextCut
NextCut is a research CAD/CAM sys-
tem from Stanford University. NextCut is
built on the philosophy that the best way to
assure Design for Manufacturability is to
design products by specifying manufactur-
ing plans for producing them. In NextCut
the user simultaneously designs a product
and the process used to manufacture it. De-
signers work in manufacturing modes (e.g.,
machining, molding, or assembly) adding
features to a design or directly manipulat-
ing the process plan. An important aspect
of manufacturing modes is that the user in-
terface, and the features and operations that
a designer works with, reflect the character-
istics of the materials and processes under
consideration. For example, machining
mode supports material removal while as-
sembly mode allows the designer to put
things together. Manufacturing ex-
perts (or expert systems) check the
resulting plans and fill in details af-
ter each step to ensure that no func-
tional, geometric or manufacturing
constraints are violated.
Status:
The current version of NextCut
is installed on the Sun 4/330. Next-
Cut runs on the Sun 4 workstation,
and requires both Sun CommonLisp, Symbolic Programming Envi-
ronment and Sunview for execu-
tion. NextCut is also available on
the TI Explorer.
Further Reading:
Cutkosky, Mark R., Jay M. Tenenbaum,
Dieter Muller, Features in Process-
Based Design . ASME CIE Conference,
San Francisco, July 1988.
Developers:
Mark Cutkosky
Department of Mechanical Engineering
Stanford University
Stanford, California 94305
(415) 725-1588
Jay M. Tenenbaum
Center for Integrated Systems
Stanford University
Stanford, California 94305
(415) 725-3623
PILLOW-PROCESS
SELECT-FIXTURE-2 SELECT-FIXTURE-3
SELECT-TOOL-4 SELECT-TOOL-5 SELECT-TOOL-S SELECT-TOOL-7
CUT-4 CUT-5 CUT-6 CUT-7
This illustration shows a portion of a process plan on NextCut.
Page 8 Engineering Design Lab Guide
Allison Barnard Feeney N-See
N-See
N-See™ is a commercially available
Numerical Control (NC) verification pro-
gram. N-See allows you to see your work-
piece as actually cut, both in-process and as
a final part. N-See is based on a general-
ized octree solid model. The part is dis-
played in a realistic fashion and can be
rotated, sectioned or zoomed at any time.
Some of the capabilities supplied by N-See
are simulation and verification of 2 and 3
axis milling operations, tool set up, and line
by line execution of G-codes. All G-codes
accepted by an ISO/FANUC/Japan Indus-
trial Standard G-code are supported.
Status:
The current version 1.15 of N-See is in-
stalled on the IBM PS/2 in the EDL. In
general, N-See runs on a 286, 386 or 486
based PC with an EGA or VGA graphics
board, serial mouse, and math co-proces-
sor.
Further Reading:
N-See User’s Manual . Microcompatibles,
Inc., Silver Spring, 1989.
Developer:
Donald M. Esterling
Microcompatibles, Inc.
301 Prelude Drive
Silver Spring, Maryland 20901
(301) 593-0683
Engineering Design Lab Guide Page 9
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Parasolid Allison Barnard Feeney
Parasolid
Parasolid is a commercially available
kernel-based solid geometric modeling sys-
tem. Parasolid library functions construct
exact boundary representations with fully
integrated parametric surfaces. One can
build models with simple surfaces, rolling
ball blends, and rational Bezier surfaces.
Parasolid supports assemblies, various geo-
metrical construction entities, and limited
graphical output such as hidden lines and
tessellation. In addition, user defined at-
tributes can be attached to topological and
geometric entities, and items in the data-
base may be grouped together as features
and manipulated by local operations. Bod-
ies may be created by use of 3D primitives
or by sweep operations on sheets or wires
defined by bezier surfaces or curves. Bod-
ies may be modified by solid set operations
on sheets or solids, sectioning of bodies,
sectioning with parametric surface sheets,
and mirroring and repositioning of bodies.
Local operations on bodies include: adding
fiUets and chamfers, rotation and linear
translation of faces, copying or removing
groups of faces to create a new body, mov-
ing or rotating groups of faces within the
existing body, and representing rolling ball
blends with special implicit blend surfaces.
Status:
We are using Parasolid with ICAD and
in other functions within the EDL. Parasol-
id is also currently being used to support
STEP efforts at NIST. We have version 2.2
running on the Sun 4 workstation. Addi-
tionally, Parasohd runs on a variety of engi-
neering workstations (e.g. Apollo, DEC,
HP, and Sun).
Further Reading:
Overview of Parasolid , Shape Data Limit-
ed, Cambridge, England, 1988
Parasolid 2.0 Reference Manual . Shape
Data Limited, Cambridge, England,
1989.
For information within the US contact:
Ron Davidson
McDonnell Douglas Manufacturing and
Engineering Systems Company
325 McDonnell Boulevard
Hazelwood, Missouri 60342
(714) 952-6117
This hidden line image was generated in Parasolid.
Developer:
Shape Data Limited
Parker’s House
46 Regent Street
Cambridge CB2 IDB, England
(0223) 316673
Page 10 Engineering Design Lab Guide
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Allison Barnard Feeney Supporting Hardware and Software
Supporting
Hardware andSoftware
Sun Microsystems
The backbone of the EDL is a Sun 4/
330 SPARC based server with 32 mega-
bytes of physical memory, GX graphics ac-
celerator board, color monitor, 2.3 giga-
bytes of hard disk storage and an 8 mm tape
backup system. The software installed on
this machine includes the Sun operating
system, X Windows, Sun Common Lisp,
Symbolic Programming Environment,
Parasolid solid modeling system. Hoops
graphics software, COSMOS/M finite ele-
ment analysis software, ICAD design sys-
tem, emacs, and Framemaker desktop
publishing software.
Additionally, there are two SPARCsta-
tion 1 computers equipped with 16 mega-
bytes of physical memory, local disks,
color monitors, and graphics accelerators
and two Sun 3/80 workstations, each with
16 megabytes ofmemory and monochrome
monitors.
Silicon Graphics
The EDL is home for a Silicon
Graphics Iris 2400 Turbo. The Iris has 12
megabytes of memory, hardware floating
point and hardware Z-buffer. Installed
software on the Iris includes Common Lisp
and Alpha_l.
IBMAn IBM PS/2 Model 70/A21, with an
Intel 486 power platform, 8514 color mon-
itor and graphics system, 8 megabytes of
memory, 120 megabyte hard disk, ethemet
card, DOS 3.31, and IBM ADC is an integral
part of the design lab. Installed software
packages include N-See verification soft-
ware, Turbo C and Turbo C+-i- program-
ming environments, WordPerfect 5.0,
CADKEY CAD package, and COSMOS/M finite element analysis software.
Apple
Also in the EDL is an Apple Macintosh
nx, with 8 megabytes of physical memory,
160 megabyte internal hard disk, 24 bit col-
or board, a WORM optical 5.25 inch drive,
and two removable 45 megabyte drives.
Additional hardware includes a Howtek
Scanmaster color scanner and Tektronix
4693DX color printer. The Mac n runs
TOPS, a C programming environment, and
numerous paint and publishing packages.
Communications
All of the systems in the EDL are con-
nected via Internet to the outside world and
to other systems at NIST.
Engineering Design Lab Guide Page 1
1
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Facility Allison Barnard Feeney
Facility
The Engineering Design Laboratory is
located in Building 304, Room 5 at the Na-
tional Institute of Standards and Technolo-
gy in Gaithersburg, Maryland. The above
diagram outlines current configuration of
the physical facility. Any questions, com-
ments or suggestions concerning the facili-
ties or the design research conducted in the
EDL are welcomed.
Contact:
Peter F. Brown, Project Manager
Machine Intelligence Group
Factory Automation Systems Division
National Institute of Standards and
Technology
Metrology Building A 127
Gaithersburg, Maryland 20899
(301) 975-3544
Page 12 Engineering Design Lab Guide
Allison Barnard Feeney Research Opportunities
Research
Opportunities
With the Omnibus Trade and competi-
tiveness Act of 1988, NIST was designated
the federal government’s catalyst for
speeding innovation and accelerating the
adoption of new technologies and ideas by
U.S. companies. This legislation opens up
even more avenues for cooperation be-
tween NIST and universities, industry, fed-
eral laboratories, state and local
governments—any organizations that have a
stake in helping U.S. business compete
more effectively in the world market.
One of the most popular ways NIST fa-
cilities are made available to industry is
through the Research Associate Program.
In this program, organizations sponsor re-
search associates to work at NIST, provid-
ing salary, fringe benefits, and travel, while
NIST provides use of the facilities, equip-
ment and its broad base of expertise.
Another type of cooperative venture in-
volves the donation (or loan) of software
and/or hardware for use by NIST research-
ers on projects that could ultimately im-
prove a company’s product or way they do
business. In these cases, companies mayadvise NIST researchers on the needs and
concerns of the industry.
The scope, duration, and structure of
the research agreements are determined by
the problem to be solved. These agree-
ments can last from a few weeks to years
and can involve one or many organizations.
The goal at hand is to solve the problem ef-
fectively and efficiently.
Contact:
David E. Edgerly
Director, Office of Research and
Technology Applications
Room A573, Building 301
National Institute of Standards and
Technology
Gaithersburg, Maryland 20899
(301) 975-3087
Engineering Design Lab Guide Page 13
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NIST-114A U.S. DEPARTMENT OF COMMERCE(REV. 3-90) NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY
BIBLIOGRAPHIC DATA SHEET
1 . PUBUCATION OR REPORT NUMBER
NISTIR 45192. PERFORMING ORGANIZATION REPORT NUMBER
3. PUBUCATION DATE^
. FEBRdSy -1^14. TITLE AND SUBTITLE
Engineering Design Laboratory Guide
5. AUTHOR(S)
Allison Barnard Feeney
6. PERFORMING ORGANIZATION OF JOINT OR OTHER THAN NIST. SEE INSTRUCTIONS)
U.S. DEPARTMENT OF COMMERCENATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGYGAITHERSBURG, MO 20899
7. CONTRACT/GRANT NUMBER
8. TYPE OF REPORT AND PERIOD COVERED
9. SPONSORINQ ORGANIZATION NAME AND COMPLETE ADDRESS (STREET. CITY. STATE, ZIP)
10. SUPPLEMENTARY NOTES
11. ABSTRACT (A 200-WORD OR LESS FACTUAL SUMMARY OF MOST SIQNIRCANT INFORMATION. IF DOCUMENT INCLUDES A SIGNIFICANT BIBUOQRAPHY ORLITERATURE SURVEY, MENTION IT HERE.)
This document provides a brief description of the systems available for use in the
Engineering Design Laboratory at the National Institute of Standards and Technology,Gaithersburg, Maryland. The Engineering Design Laboratory was established to study the
process of design, how design information can be represented, and how to make designinformation available to necessary systems throughout a product's life cycle. This
document also discusses opportunities for collaborative or independant research in the
Enginearing Design Lab.
|l2. KEY WORDS (6 TO 12 ENTRIES; ALPHABETICAL ORDER; CAPITALIZE ONLY PROPER NAMES; AND SEPARATE KEY WORDS BY SEMICOLONS)
Apparel design, design laboratory, finite element modeling, knowledge based software,
solid modeling
11 AVAU-AAIUTV 14. NUMBER OF PRINTED PAGES
X UNUMITED
FOR OFFICIAL DISTRIBUTION. DO NOT RELEASE TO NATIONAL TECHNICAL B4F0RMAT10N SERVICE (NTIS).
1^'
ORDER FROM SUPERINTENDENT OF DOCUMENTS. 0.S, GOVERNMENT PRINT1N0 OFFICE,
WASMNGTON, DC 20402.
15. PRICE
A02"x- ORDER FROM NATIONAL TECHNICAL INFORMATION SERVICE (NTIS), SPRINGFIELD,VA 22161.
electronic form
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