Small 2 flute deep slotting aluminum

[mattthemuppet2]

1xD is a good rule of thumb for slotting. So two 0.25" DOC passes then one 0.1" pass (clearing chips gets harder the deeper you go), leaving 25 thou for a finishing pass on the bottom. I usually aim for 10-20 thou left for finishing on the walls of slots. I also use kerosene for cutting alu, works as well as WD40 but costs considerably less. Doesn't smell as nice though

If you want to chain drill, use a drill. You can plunge cut with a center cutting endmill, but it's no where near as easy/ efficient as using a drill.

 

[matthewsx]

This is the type of thread I learn from. I don't have anything to add here but am happy to be along for the ride. Pictures or it didn't happen....

John

 

[Parlo]

Use a single flute cutter. They have various flute lengths so choose the shortest one you need. Plenty of room for the chips. + all the previous stuff, coolant and compressed air.