I don't know where you got your feed and speed info from but it is way low.
Average book speed (generally low. a safe starting point) is 600 sfm. This
comes out to 4583 RPM with a 1/2" HSS 2 flute endmill. At that RPM, minimum
feed would be 9" per minute. I typically run them at 6000 RPM at 30 to 35"
per minute feed.
While there are circumstances that double sided tape can be used as a hold
down in a milling operation, this isn't one of them.
> FYI the recommended cutting speed for a 1/2" 2 flute end mill is
Thanks CW, I was being lazy and used the Rockford quick calculator (got to
delete that thing). I agree about the method of hold down, just seemed
that the general tone of the thread was that routing Al was in the same
category as sticking your hand in acid.
There are a lot of speed and feed calculators around and some of the worst I
have seen are on the internet. See a Kennametal dealer and get one of there
slide-card type calculators. They not only do feed and speed but depth of
cut and horsepower requirements for the process.
Routing aluminum works but the method the OP was thinking of was a recipe
for disaster. There is a major aircraft manufacturer that, up until
recently, made extensive use of router tables doing aluminum. These were
standard router tables, standard fixed speed routers and the parts were fed
by hand. Noisy and messy but it worked.
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