Energy-saving Optimization Of Hyperboloid Drill Grinding Parameters And Helical Groove Design Parameters

Twist drill, or drill bit, is a kind of complex-shaped tool widely used in the drillingprocess and its disadvantage is poor cutting performance and high energy consumption.Research was focused on the conical flank grinding and its drill tip optimization, so study onthe hyperboloid flank grinding and helical groove are rarely involved. Apparently, how toreduce hyperboloid drill energy consumption is an urgent problem on the background ofglobal energy crisis. This paper is committed to find feasible hyperboloid drill grinding andhelical groove design parameters using modern optimization techniques with the aim ofdrilling power minimization.First, a geometry model of hyperboloid flank twist drill with straight or curve helicalgroove occurrence is established. Based on the Planar Displaying Method, a computationmodel is developed to calculate the main edge and the chisel edge cutting angles.Then, a relational model of the grinding and helical groove design parameters betweendrilling power is developed in the light of the linear synthesis method of elementary cuttingtools. The indentation zone radius and its contribution to the axial force are calculatedaccording to the slip line field theory. Empirical cutting forces model of ECTs is establishedbased on oblique end turning experiments.To achieve minimum drilling power, a method is proposed to optimize the grinding andhelical groove design parameters based on the MATLAB Genetic Algorithm Toolbox. Theresults show that compared with the unoptimized drill, the drilling power (AISI1045steel)reduced by14.3%and11.1%on average for the optimized drill with straight and curveoccurrence respectively. Finally, a flank interference checking model is established and theresults show that flank interference will not occur on the optimized drills.