Cutting Tool Model Development

This project has successfully developed a new mechanistic modelling program and user interface for the optimisation of drill-point geometry, improving the accuracy of tools  used in defence manufacturing.

Under the leadership of industry partner Sutton Tools, a team of undergraduate students set out to create a mechanistic modelling program to predict the thrust, torque and power used while undertaking drilling operations. The team’s objective was to correct any errors found in previously published models and to further  study and derive accurate cutting force information for the required materials.

The team ensured convergence of the  models, and validated the model against production and experimental data. Finally,  they used non-linear optimisation algorithms  to optimise drill geometry. Based on the  acquired data, the team developed an optimisation program that specifies the drill geometry with minimum thrust requirements.

A user interface was then created. The software developed is open source and the algorithms have been modified to use published data for specific cutting forces. This program has broad application beyond the specific materials tested.

Further work is required to verify the optimised drill geometry with experimental drill tests. Future models could then be expanded to include more complex drill features such as curved cutting lips as well as additional drill designs.