Question: 4 - A rectangular keyway is to be broached in a cylindrical steel shaft with a hardness of 2 0 0 HB using a broaching
A rectangular keyway is to be broached in a cylindrical steel shaft with a hardness of HB using a broaching machine. The details of the operation are as follows: Length of the keyway: Width of the keyway: w mm Depth of the keyway: Cutting speed: Material removal rate per tooth: tooth, Total number of cutting teeth on the broach: Distance between successive teeth: Cutting force per tooth: Efficiency of the broaching machine: Determine:
a Total time to complete the broaching operation, considering the full stroke length includes the keyway length L plus an additional mm for setup and exit.
b Material removal rate MRR for the operation.
c Power required to perform the broaching operation.
d The force acting on the broach during cutting, assuming all teeth engage simultaneously after the first few passes.
e The total energy consumption for the operation Pts
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