As competition grows among manufacturing companies, greater emphasis has recently been placed on product aesthetics and decreasing the product development time. This is promoting and standardizing widespread use of sculptured surface styling within product design. Therefore, industries are looking for high efficiency machining strategies for sculptured surface machining (SSM). Many researchers have produced various methods in tool path generation for SSM. Five-axis curvature matched machining (CM2) is the most efficient. With the widespread use of 5-axis mill in industries, CM2 is a better solution for improving the machining efficiency for product concept models. CM2 has very good performance for global machining of single patch surface or a quilt of simple sculptured surface patches. But when CM2 is used to generate tool paths for global machining of a large region of complex sculptured surface such as the top or side skins of a vehicle, there will be some limitations, that is, the performance will be influenced greatly in some steep areas where the lead angle of the tool becomes larger to match the curvature or avoid gouging. Larger lead angles mean smaller effective curvatures at the leading edge of the tool bottom where it contacts the part surfaces. Therefore, the density of CM2 tool path is very high in these steep regions. By setting a smaller upper limit for the lead angle, the density of tool path will not be very high in the steep regions, but there will be some uncut materials. This thesis focuses on how to determine the uncut or rework areas of the previous CM2 and how to define the boundary of these regions. Strategies for generating more efficiency CM2 tool paths are also discussed. These methods will be tested by applying finish global machining to a one-fourth scale Ford GT model.

The use of pre-hardened mold steels has increased appreciably over the years; more than 80% of the plastic mold steels are used in pre-hardened condition. These steels are delivered to the customer in finished state i.e. there is no need of any post treatment. With hardness around ~40HRC, they have properties such as good polishability, good weldability, corrosion resistance and thermal conductivity. Machinability is a very important parameter in pre-hardened mold steels as it has a direct impact on the cost of the mold. In normal machining operations involving intricate or near net shapes, machining constitutes around 60% of the total mold cost. Efforts are underway to explore every possible way to reduce costs associated with machining and to make production more economical. All the possible parameters which are considered to affect the machinability are being investigated by the researchers. This thesis work focuses on the effect of prior austenite grain size on the machinability of pre-hardened mold steel (Uddeholm Nimax).  Austenitizing temperatures and holding times were varied to obtain varying grain sized microstructures in different samples of the same material. As it was difficult to delineate prior-austenite grain boundaries, experimental and empirical methods were employed to obtain reference values. These different grain sized samples were thereafter subjected to machining tests, using two sets of cutting parameters. Maximum flank wear depth=0.2mm was defined for one series of test which were more akin to rough machining, and machining length of 43200mm or maximum wear depth=0.2mm were defined for second series of tests which were similar to finishing machining. The results were obtained after careful quantative and qualitative analysis of cutting tools. The results obtained for Uddeholm Nimax seemed to indicate that larger grain sized material was easier to machine. However, factors such as retained austenite content and work hardening on machined surface, which lead to degradation of machining operations were also taken into consideration. Uddeholm Nimax showed better machinability in large grained samples as retained austenite(less than 2%) content was minimal in the large grained sample. Small grained sample in Uddeholm Nimax had a higher retained austenite (7+2%) which resulted in degradation of machining operation and a lesser cutting tool life.