This work describes the optimization process for ball-end milling of sculptured surfaces such as those encountered in dies/moulds and aircraft structural components. Since cutting forces are the main factors governing machining accuracy, machine tool vibration, power requirements and tool life, a comprehensive methodology of modelling, analysis and control of cutting forces is outlined. Due to complexity and vagueness of manufacturing process, fuzzy logic controller is employed to vary cutting parameters in real-time during manufacturing process depending on the emanating cutting forces. The control scheme aims at maximizing on the material removal rate and at the same time reducing on the rate at which the tool wears out. Also the need to have a constant machine operator to supervise the machining process is elimintated.