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From: "Marvin Kaye" <marv@lancaironline.net>
Subject: Re: [FlyRotary] Re: hand router milling
To: "Rotary motors in aircraft" <flyrotary@lancaironline.net>
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Date: Thu, 03 Mar 2005 11:13:30 -0500
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"Mark R Steitle" <mark.steitle@austin.utexas.edu> wrote:

"""
  Kevin,
  I keep a block of bee's wax near the table saw to help with cutting
  aluminum.  Also, I purchased a special aluminum cutter for my die
  grinder from the local machine tool supplier (Dixietool.com).  It has
  many fewer, but deeper flutes than ones made for ferrous metals.  It
  works really great on aluminum.  My experience showed that it gives a
  much better finish than a carbide wood cutter does and it was easier to
  control (you still need to pay attention).
"""

The attack and relief angles on cutters meant for wood vary dramatically from 
those used on metal cutters.   A [wood-cutting] router bit will get you 
through in a pinch, but a real milling cutter or burr will perform much 
better.  I use WD40 for all my aluminum machining, works really well, although 
a bit messy.  It's excellent for lubing taps when cutting aluminum.  I buy it 
by the gallon and dispense it with a plastic squirt bottle.  FWIW.

  <Marv>