[Mark Van]

I Need to clean up the ends of some aluminun extrusions Similar to 80-20 (3" x 4.5" ). My Lowest router speed is about 10.000RPM. Can this be done with a .500" high speed end mill. I can Rig up a mist or whatever I need and about any feed speed. Any advice? Thanks.

[mishikwest]

That'll work just fine. Use a 2 or 3 flute endmill, something that clears chips well. Hss may not last all that long, a solid carbide will last you forever.

Depending on how much you have to remove, chip evacuation will be your biggest issue. Mist if you can, flood is best. Feeds? That's gonna be more dependent on rigidity of setup, machine torque, depth of cut etc. I'd start with 50ipm and go from there (probably up) If your only taking light cuts, you may even find that something in the range of 200ipm will work.

[ViperTX]

I would just use a carbide router bit....probably a plunge cutting rabbetting bit 1/2" diameter or larger.

[Mark Van]

Thanks for the info.