Here are the things where I need your expert advise on a CNC Router that runs on Mach2 software:


1. The cuts are very rough. I am using a 2-flute HSS end mill should it be better if I try climb milling instead of conventional milling.

2. How can I optimize use of end mill cutting edges. I mean when I plunge and mill it uses certain area of the end mill but rest is un-touched. How can I make use of rest of the surface ?

3. Currently I am using a 2 step carbide with TiN coated drill bit (photo attached) to drill 0.156" and 0.200" holes on Anodized Aluminum Extrusion using a porter cable installed as a second head on this CNC Machine. The problems which I am facing are:



The RPM of the drilling head is 25000. The feed is 7.5. Due to the high R.P.M. the drilling head makes terrible noise. I tried to reduce the speed but the drill bit broke at the edge.

The holes has burs left at the bottom or melted.

The burs sticks / melts to the flute. I am using air as a coolant.

Can you advise me on speed, feed, RPM, material or coating of the drilling bit,…etc. Any thing that can help me in getting this resolved.