[joeyjrc]

I can't use a half inch because the corners call for a .188 radius. I had my HSS end mill running 1500rpm and 3 ipm. I drilled a 3/8 hole in one of the corners to full depth and used that as my plunge spot. I don't have cam software, I write all my code by hand. I'm an experienced machinist and I know how to cut metal I'm just not too experienced with my tormach and what it can do in aluminum.

[mike sr1]

In aluminum I would run the rpm 5140, full flood coolant.A 3/8 endmill may chatter some in the corners as the radius is the same size as the cutter.

As Russ suggested lighten up on the doc .125 is too much for that size long length cutter.

Another option is to hog it out with a .5 cutter then finish with the .375

The Tormach will pull that cutter just fine.

[joeyjrc]

Thanks, I'll give that speed and feed a try with less depth of cut. I would like to keep it to 1 tool so I can just use an r8 collet instead of the tormach holders, I like the holders but the end mill will be hanging out even more with one. The r8 direct in spindle is more rigid.
Thanks again,
Joe