I have been cutting aluminum for quite a few years, so I have a few questions:
1) You haven't really identified which machine you would like to optimize.
2) What kind of controller is on the Fadal? (if this is the machine that you are concerned with)
3) What does the part look like? This is integral to the method of machining.
4) 2d profiling and "contouring" are almost the opposite of each other. (again lets see what you wish to cut)
5) Is roughing at .005" per side? Or is there a semi stage involved?
6) what kind of aluminum?
IMHO, if you were planning to rough on any machine to .005" per side, you had better use all of the look ahead features available to the cnc machine!
Also, you have to consider how much you wish to mash up your bread-and-butter......meaning, if you run the machine at 4-500ipm and its bouncing around like a jackhammer........what does that benefit? Forget about tolerances when the thrust bearings are flattened out. (aka fadal cnc88hs syndrome)
In my experience, cutting 2d or 3d, if you semi to a thickness of .011" per side at maximum machine feedrate using contour contol, finishing thereafter at approx. 100ipm, will leave no stock...as long as cutters are sharp and contour control has been activated.
But that's pretty general...like I said, let us see what it is you are trying to machine.
Hope I can be of some help.......and maybe learn something here at the same time.
Cheers!
"'Tis a poor workman who blames his tools."