The role of FE simulation in the optimisation of hardmetal rotary-percussive drill bits and cold forming tools

• A virtual FE geometry DoE identified improved drill bit designs.
• FE analysed operational stresses in forming tools to predict failure locations.
• Shortcomings in material input parameters are highlighted.
• Potential improvements in FE modelling techniques and input data are described.

This paper demonstrates the significant role of finite element (FE) simulation/modelling in the optimisation of cemented tungsten carbide drill bits and forming tools. Two case studies are presented, one from the development phase for a new product and the other from the continuous improvement process during mass production. Additionally, a number of important issues are raised concerning the material property data used for FE simulation, the interpretation of results generated, and approaches to bring FE a step closer to simulating real components and operating conditions with greater predictive accuracy regarding the failure probability of the component in service.