**4. Main concerns about the manufacturing process of free form geometries**

In the contemporary world the manufacture of free form geometries is carried out first by milling and electrical discharge machining (EDM) when necessary. Newer manufacturing process has been developed such as fabrication by deposition, like as the rapid prototyping, but yet the first both process are still the mainly ones and they are taken into account in this chapter.

Usually, milling is the first option due to the inconveniences of the EDM processes, because EDM it requires an extra effort to modelling the electrodes, CNC programming and milling the electrodes, time consumption for EDM machining itself, besides the EDM can injure the machined surface integrity. The EDM process is used where the milling tool cannot reach due to geometry limitation, or it may be required in specific cases. The 5 axis milling is a drive force for manufacturing free form shapes, once that the cost are reducing and the technology is getting raising.

For milling complex forms the generation of CNC programs should be fulfilled by a CAM system. The user should initially have a geometric model of CAD 3D, which should be used by CAM as a base to calculate the tool path. After the calculation the route of the tool should be simulated and subsequently coded in commands, which should be interpreted and transformed by the CNC machine in movements and actions. The Figure 4 illustrates the procedure to manufacture a free for geometry by CAM software.

Besides, CAE (Computer Aided Engineering) software can be used to simulate the product mechanical requirements or the manufacturing process. However, in most of the times it is not essential for free form manufacturing such that mentioned above. You can find a detailed description about the CAx for free form modelling and manufacturing ahead in this

**4. Main concerns about the manufacturing process of free form geometries**  In the contemporary world the manufacture of free form geometries is carried out first by milling and electrical discharge machining (EDM) when necessary. Newer manufacturing process has been developed such as fabrication by deposition, like as the rapid prototyping, but yet the first both process are still the mainly ones and they are taken into account in this

Usually, milling is the first option due to the inconveniences of the EDM processes, because EDM it requires an extra effort to modelling the electrodes, CNC programming and milling the electrodes, time consumption for EDM machining itself, besides the EDM can injure the machined surface integrity. The EDM process is used where the milling tool cannot reach due to geometry limitation, or it may be required in specific cases. The 5 axis milling is a drive force for manufacturing free form shapes, once that the cost are reducing and the

For milling complex forms the generation of CNC programs should be fulfilled by a CAM system. The user should initially have a geometric model of CAD 3D, which should be used by CAM as a base to calculate the tool path. After the calculation the route of the tool should be simulated and subsequently coded in commands, which should be interpreted and transformed by the CNC machine in movements and actions. The Figure 4 illustrates the

Fig. 3. Some CAx application on free form manufacturing

procedure to manufacture a free for geometry by CAM software.

chapter.

chapter.

technology is getting raising.

Fig. 4. Procedure to manufacturing free form geometries by CAM software

The mainly features of free form milling can be listed as following.
