[sanddrag]

Originally Posted by DonRotolo

Contrast that with sheet aluminum (6061), with my 1/4" bit I can cut 1/4" thick material single-pass at 50 IPM...As long as the coolant mist and compressed air are on. Chip management is critical for Aluminum, or bits will break.

I take it this is slotting, full width, with an Onsrud single flute bit? Still, that seems like a rather hefty cut. FSWizard tells me to go something like 18,000 RPM at 34 inches per minute for 6061 aluminum, a 60 degree helix angle 1/4" single flute bit, in 1/4" 6061 aluminum, full depth, slotting. It says it will take 0.6 Horsepower for this cut. I wonder if my Porter cable would be able to do this cut.