ive got a 1997 dyna mechatronics mini mill. it weighs about 1500lbs (alot of that might be the platform and drip tray base which are both heavy).

it can rapid at 200ipm, but id only trust it at 150ipm, seems like alot of inertia at 200ipm

it has flood coolant and a 2hp spindle, and can run at 7000rpm, or 10000rpm if i get a pulley upgrade

id like to push it as hard as possible as far as material removal rates in aluminum..im wondering if anyone might have tips for a strategy besides the basics like simply experimenting with endmills and feed rates...im thinking the following might be a place to start:

-see if i can get my hands on hsm toolpath software like volu-mill
-try high helix aluminum-specific endmills
-get the 10000rpm pulley set for my mill

some questions i have:

-seems like youtube videos of HSM in aluminum use air blast instead of flood coolant..not sure at what point i should change to that..
-not sure if 1/4" is better than 1/2" when it comes to very high speed machining....1/2" is more rigid but will need more power and rigidity...1/4" needs less rigidity but doesnt remove as much material and is flimsier


anyone attempt to max out their mini mill in aluminum?