Hi, guys. I am a grinder in a powdered metal tool and die shop. A few times a year we have to build some kind of O.D. splined form punch. So, our CNC mill man will rough the spline form on the mill, then heat treat, then it comes to me for finishing. Depending on the form, mostly on the base radii, I may either CNC jig grind the O.D., or dress the tooth gap form onto an aluminum oxide wheel and set up the punch on a 4th axis fixture on a manual surface grinder. Sometimes I may have a gage plate to test for die fit, sometimes I may have the actual die. But what usually ends up happening is, no matter how meticulous I am with measurements, the punch will bind in the die somewhere I know not where, and I end up LAPPING the punch into the die itself. This cause me varying amounts of grief, depending on the size, (mostly weight), of the punch. I have done this several different ways, the last couple big ones I have done, I have actually set the die up in our big lathe chuck, and engineered some way to attatch the punch to the tool post, using the lathe the hold things steady while moving the Z in and out and in and out and in and out until it fits. Very short version, it's a GREAT BIG PAIN. I'm guessing a lot of folks would just EDM sink the punch with a wire cut electrode. Any other powdered metal guys out there without a good EDM man do things like this? I have about 7.5 yrs experience in powdered metal stuff. First, in a production factory running CNC lathes in secondaries, now as a tool and die man for the past 4.5 yrs. So, not an old hand at this. Is there any such thing as a purpose built machine that I could attatch both punch and die to that would do this for me automatic-like? I'll take whatever advice y'all may have, Thanks.