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PSA: stop running your finish pass at full spindle speed on aluminum
I keep seeing new guys on the floor crank the RPM to the max for a finish pass on 6061 and then act shocked when the part comes out with chatter marks and a fuzzy edge. Had a kid on my shift do it twice in one week on the same batch of brackets, and the second time he wrecked a 3 flute carbide endmill that cost us $47. Aluminum pulls heat away fast, so you can run hard, but finish passes want a lighter chipload and a steady feed, not just redline RPM. Dial it back, keep the feed smooth, and watch your surface finish jump. What feed and speed are you all running on your finish passes for 6061?
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