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Twist drills are geometrical complex tools and thus various researchers have adopted different mathematical and experimental approaches for their simulation. The present research acknowledges the increasing use of modern CAD systems and subsequently using the API (Application Programming Interface) of a typical CAD system, drilling simulations are carried out. The developed DRILL3D software routine, creates, via specifying parameters, tool geometries, so that using different cutting conditions,  realistic solid models are produced incorporating all the relevant data involved (drilling tool, cut workpiece, undeformed chip). The 3D solid models of the undeformed chips coming from both cutting areas (main edges and chisel edge) are segmented into smaller pieces, in order to calculate every primitive thrust force component involved with high accuracy. The resultant thrust force produced, is verified by adequate amount of experiments using a number of different tools, speeds and feed rates. The final data derived, consist of a platform for further direct simulations regarding the determination of tool wear, drilling optimizations etc.







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