Hi everyone, I'm kinda stuck trying to do boring operation on my Alu plate, I have used initially 3/16 inch 2 flute carbide end mill with speeds and feeds recommended by hsmadvisor/Fswizard and what happens is that either spindle overloads and everything halts or noise is so bad and I stop it, just to find out the alu got stuck in big pieces in the flute channels! scary and I had to remove them with pliers. tried a 6mm ball nose carbide end mill hoping that since it was higher quality it would cut okay, still same issue and alu would gum in the end mill a bit and noise and everything just isnt right. probably because of the aluminium getting glued to the end mills haha

what do I do? is using 2 flute end mills wrong? is the size wrong? I have a 2mm 2 flute end mill but I wouldnt be able to get it all the way down to my required depth due small length and shaft being bigger than 2mm.

please appreciate your guidance on how to proceed