Hi.

Been running my diy router for about 6 months now, and it performs perfectly in most situations.

I had a guy approach me last week asking to have house numbers cut out of alu. I took the challenge and have started experimenting with light cuts in a piece of scrap.

I've been trying to do a profile cut in the full depth of the material (15mm, .6in) and there are no problems until I almost cut through (about 12mm in I guess), then I get alot of chatter and vibrations and have to shut down. It seems like it might be due to buildup of chips.

The bit is a 6mm 2 flute end mill. Running at 12000 rpm and 120mm/sec feed rate taking 0,5mm cuts. Have tried several different settings but seem to churn out the same result every time. For coolant and chip clearing I use CRC (ie. WD40) and compressed air. Not sure what spec the alu is.

Any suggestions what I might try next?