Part I of this work presents a combined one-dimensional/three-dimensional approach for obtaining a unified model for the dynamics of micro- and macro-drills. To increase the numerical efficiency of the model, portions of the drill with circular cross-section (shank, extension, and tapered sections) are modeled using one-dimensional beam models without compromising model accuracy. A three-dimensional model is used for an accurate representation of the fluted section, considering the actual geometry with the pretwisted shape and axially varying (nonaxisymmetric) cross-section. The actual cross-section of the drills is incorporated to the model through a polynomial mapping while the pretwist effect is captured by defining a rotating reference frame. The boundary-value problem for both one- and three-dimensional models are derived using a variational approach, based on the extended Hamilton’s principle, and are subsequently solved by applying the spectral-Tchebychev technique. A component-mode synthesis is used for connecting the individual sections to obtain the dynamic model for the entire drill. Convergence of the model is studied by varying the number of polynomials for each section. The experimental validation of the model is included in Part II for both macro- and micro-drills. Also included in Part II is an analysis of drill dynamics for varying drill-geometry parameters and axial (thrust) force.

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