Re: Alu - best roughing tool
As others have said, insert type mills are not the best for low power machines. They are not as sharp and don't have the optimum chip relief.
Many years ago, SGS came out with what they called the Ski-Carb or something like that. It was a combination of higher helix and different lands after the cutting edge. The were expensive at about $150.00 for a half inch endmill, but they were great for high metal removal. The are still made, but they are now others. There used to be a patent on the design, but I believe it has expired.
Alu-Power is what I use now.. They are made overseas somewhere but I buy them off of eBay. Very nice finish and you can push them hard. They are very inexpensive for how good they work. While they are center cutting, they don't plunge well and tend to load up in the center. I generally enter a hole for them. But after that you can really remove a lot of material.
Below is a link to a 3/4" one, but I use 1/2" and 5/8".
3/4" YG1 Alu-Power 3 Flute Regular Length Carbide End Mill for Aluminum | eBay
Mike
Two Haas VF-2's, Haas HA5C, Haas HRT-9, Hardinge CHNC 1, Bother HS-300 Wire EDM, BobCAD V23, BobCAD V28