Question 1: Explain the following terms and situations in metal cutting. Give enough explanation with figures if it is necessary. a) Up and down milling operations. What are the effects on the workpiece surface finish and machine tool? b) Orthogonal and oblique cutting. c) Cutting force diagram in orthogonal cutting.

Question 1: Explain the following terms and situations in metal cutting. Give enough explanation with figures if it is necessary. a) Up and down milling operations. What are the effects on the workpiece surface finish and machine tool? b) Orthogonal and oblique cutting. c) Cutting force diagram in orthogonal cutting. d) Theoretical prediction of shear angle in orthogonal cutting. e) Machinability. f) Force and chatter vibrations. How can you detect the vibration during the machining? How can you decide which type of the vibration you have? g) Mode shapes. Mode coupling. h) Process damping. Which parameters can affect the process damping? i) j) Regenerative chatter vibrations. k) Stability lobes. Question 2: How will the cutting force be affected by the following situations during the machining operation? Why? a) Large rake angle b) Small relief angle c) Large nose radius d) Sharp cutting edge e) Smooth rake face f) Hard workpiece material g) High cutting speed h) Large feed rate i) Small depth of cut j) Large width of cut k) Vibration Question 3: a) Discuss the tool wear with different values of Relief (flank or clearance) angle, Rake angle, Cutter nose radius and Cutting edge honing. b) Which type of the cutting tool material can be used for high productivity and good quality with reasonable cutting tool and machining time cost in turning and milling operations? Aluminum machining (at low cutting speed) Aluminum machining (at high cutting speed) Nickel based super alloys (roughing) Nickel based super alloys (finishing) Titanium alloys c) Please discuss the following values on the workpiece and tool depending on the machine tool vibration and rigidity? Deflection Surface finish Tool wear Part quality Question 4: How many deep hole-drilling approaches exist? Explain them with figures. What are the important points in deep hole drilling operation? Question 5: Explain mechanics of drilling by looking at the chip and force generation. Question 6: How many different types of the vibration can occur during the metal cutting? Please explain them shortly. How can the vibration be detected during the machining? How can be decided for the type of the vibration? Question 7: Give five nontraditional process names and explain only one of them