I'm always having issues cutting aluminium on my mill. The side which is climb milled is not too bad, but the side which is conventional kind of grows a furr of re-cut aluminium.

The thing is, I have a reasonably decent vacuum above the cutter and I've tried all different feeds and speeds (have G-wizard).

What I notice is that the issue becomes far worse as cutting time goes on and the piece heats up. Does anyone think the heat of the aluminium could be an issue? It seems like it becomes 'sticky' when it gets hot and bungs up my cutter and chips don't extract well.

I tried a 2 flute cutter today and it seemed to work better than the 1 flute but then suddenly got cloged as in the picture below.

Has anyone else experienced similar? I realise coolant is the way to go, but I don't really want everything to be messy and wet! Maybe a mist spray would be a good middle ground.

Some pictures..





Below: This was extracted from the groove part way through cutting.