ABSTRACT
The functional part geometry of a mold (or simply referred as a mold in this chapter), such as in the core and cavity, often includes sculptured surfaces. Traditionally, milling of sculptured surfaces in a mold was done by copy milling. However, as the cutting tool engagement condition is unfavorable, this method can result in tool deflection and machining inaccuracies. Instead, Computer Numerical Control (CNC) milling and Electrical Discharge Machining (EDM) are the two most important machining methods in die and mold manufacturing. In general, a die or mold is usually machined by the more efficient CNC machines first. If there are regions that are too intricate for a milling cutter or the material is very difficult to machine, EDM is used.
