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

4- A rectangular keyway is to be broached in a cylindrical steel shaft with a hardness of 200 HB using a broaching machine. The details of the operation are as follows: Length of the keyway: L=150mm, Width of the keyway: w=20 mm, Depth of the keyway: d=6mm, Cutting speed: vc=10mmin, Material removal rate per tooth: MRR=0.2mm3? tooth, Total number of cutting teeth on the broach: nt=30, Distance between successive teeth: p=4mm, Cutting force per tooth: Ft=200N, Efficiency of the broaching machine: =85%, Determine:
a) Total time to complete the broaching operation, considering the full stroke length includes the keyway length L plus an additional 20 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 [25 Pts].
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4 - A rectangular keyway is to be broached in a

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