The paper presents a methodology to optimize drill bits to realize safe drilling of bone materials for many surgeries like orthopedics and neurosurgery. First, a mechanistic model is introduced to relate drilling forces to main drill bit geometry parameters. Then a genetic algorithm is developed to optimize drill bit geometry parameters by minimization of drilling forces based on the mechanistic model. Finally prototypes of drill bits with optimized geometry parameters are produced and drilling experiments are conducted to verify the advantages of these new drill bits. The results show that by comparison with normal drill bit, the average drilling forces are reduced to more than 50% by drill bits with optimized geometry parameters under a wide range of drilling conditions.

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