Tool sizes and tool changes

[analogman]

I am milling some .080 aluminum sheet with a large number of thru holes range in size from .125 to 1.0. A couple of questions:

(1) should I just use a .125 end mill for all operations?

(2) for the .125 holes, is it better that I change tools to a drill, or can I use a end mill OK?

(3) for the large holes, can I just do an inside profile, leaving behind a little disc, or is it better to do like a pocket and mill out all the material - these are all thru holes.


thanks for the help!
AM

[BobF]

It needs to be a center cutting end mill since at least for the .125 it is a plunge cut completely. Set the plunge speed low. If you cut an inside profile, and leave a disk, you will launch the disk unless there is something holding it down.
Look at the Onsrud cutter site for feeds and speeds in aluminum.