Broaching process – key advantages in production Which of the following best summarizes the principal advantages of broaching for internal and external profiles in mass production?

Introduction / Context:
Broaching uses a multi-tooth tool with progressively increasing tooth heights to remove material in one pass. It is a go-to process for keyways, splines, internal gears, and complex profiles where repeatability and productivity are essential.

Given Data / Assumptions:

• Properly designed broach with roughing, semi-finishing, and finishing teeth in sequence.
• Workholding provides accurate alignment (e.g., in a vertical or horizontal broaching machine).
• Suitable material and adequate lubrication are used.

Concept / Approach:
Because a broach combines many cutting edges, each removing a small increment, the total stock is removed steadily and quickly, achieving high material removal rates with low per-tooth load. The last few teeth are sized to produce the final finish and dimension, delivering excellent accuracy in a single pass. This inherent sequencing enables simultaneous roughing and finishing.

Step-by-Step Solution:
Identify broach design: progressive teeth for staged stock removal.Productivity: multiple teeth engage simultaneously ⇒ high output.Quality: finishing teeth size the profile for accuracy and finish.Conclusion: all listed advantages apply.

Verification / Alternative check:
Industrial cycle-time studies consistently show broaching outperforms shaping or slotting for repeated internal profiles, with tight dimensional control.

Why Other Options Are Wrong:
“Only suitable for soft metals” is false; broaching is used on steels, cast irons, and superalloys with appropriate tool materials and parameters.

Common Pitfalls:
Ignoring tool re-sharpening intervals; misestimating pull force; inadequate chip evacuation for deep internal broaching.

Final Answer:
All of the above