"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>