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Advice on cutting and tumbling small shaft key

The cut you pictured looks good on the part held by the vice, try holding the other part down with a clamp and see if you can get a clean cut all the way through. You can see where part isn't quite call all the way through when the burr let go and it pushed away from the blade.
 
What about farming it out to a local fab shop that has a metal cutting laser?
We don't use them that much.
Also I replaced the blade from Harbor Freight with different one and it seems it cuts better. I will try to clamp the cut off piece and see if that will help. If it does then I will do some thinking on how to add toggle clamp to the saw.
 
3 days to make 200 of these things? Wow. Been a while since I was a part of a factory scene like that.

A vertical bandsaw and a miter gauge with a stop would reduce cutting time to a third, minimum - no clamping needed.
 
3 days to make 200 of these things? Wow. Been a while since I was a part of a factory scene like that.

A vertical bandsaw and a miter gauge with a stop would reduce cutting time to a third, minimum - no clamping needed.
Union workers
 








 
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