A friend ask me to cut out some badge blanks from .020 inch thick aluminum. I loaded the file and made a couple attempts to do so but the cuts are not very clean. There is some detail in the shape so I want to use a 1/16 bit. Any recommendations on a bit, feeds and rpm to get a clean cut?
Need your bit specifications? That thin I’d use a single flute. And again, that thin, if your hold down methods aren’t gripping both the drop and the finish piece real well … it’s going to leave a poor edge finish. I’ve never had any luck using .06 bits on aluminum with any shaft less than .25".