Like many engineers, I'm always looking to design-out potential problem areas. Getting back to corner radii in 'fit' type pockets, I prefer the relieved corner approach to trying to control min/max radii. (see attached)
If you design (if feasible) the corner such that even a non-radius 'male'...
"8. Avoid designing parts that have corners the same size as a typical end mill diameter. Adding .20 or .30 to any corner with a standard diameter will lessen the surface area coming into contact with the part."
As an engineer who spent most of his former life in my father's mold shop making...
