Quote Originally Posted by matt-b2 View Post
With regards to just using cold air, I've never had much luck cutting aluminium dry. I use uncoated carbide tooling and regardless of what speed I'm cutting at, I always end up clogging my cutters without some sort of lubrication present.

Matt.
Well your doing it wrong then. I cut dry pretty much all the time using Carbide tooling with just touch of air and odd squirt of coolant.

Your most likely cutting too Shallow. Carbide likes to be worked hard.
Another Myth is that single and Twin flute cutters are needed for Ali. 3 flute work perfectly well and allow higher feed rates with more DOC.

My Standard setup is 3 Flute serated edge roughing cutter followed with 0.35 finish pass with Twin flute. The Rougher allows quick stock removal with high DOC.