Hi Machine 1
Using endmills are a thing of the past. We have specially designed carbide cutters to cut aluminum.
they work great with no chatter taking a depth of .500 to .750. in depth and working your way down at a 150 IPM
Depending on how your machining this manually or CNC will determine weather you are able to look into these types of cutters. They range from 5" to 1" in diameter. Here is a website where we buy our tooling if you are interested.
http://www.ramstar.net/