I'm having real problems with end mills breaking whilst milling 6082T6.
Machine: Emach router/miller
Cutter: 3mm carbide end mill for roughing, 2mm carbide two flute end mill to finish
Depth of cut: .3mm per pass
Coolant: oil based cutting fluid through mister system
Software: Vectric VCarve Pro 6.5
I'm using 6082 because several people more knowledgeable than me recommended this as the best grade for machining, but am breaking cutters at a rate. Feeds and speeds look about right according to GWizard. I'm cutting the word 'Bentley' in relief on badges to be fitted to engine rocker covers for vintage Bentley cars.
I don't need any structural strength from these items, so should I be using a different grade of ally?
Any help to reduce my increasing cutter bill and rising frustration would be appreciated.
Thanks a lot.