The optimization of solid carbide twist drills is a very difficult task because of the large number of conflicting design parameters. Former approaches only consider limited design aspects. This article introduces a new holistic simulation-based method for multi-objective twist drill geometry optimization. By using a complete geometry model, numerical simulation models calculate all major properties of the drill. In detail structural stiffness and strength, torque and thrust force, coolant flow resistance, chip evacuation capability and chip flute manufacturability are calculated. Several multi-objective algorithms and evaluation methods are implemented. Hence an entire geometry optimization considering manufacturability and performance is possible.

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