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12-01-2021 #1
No direct experience here as I mainly do woodwork.
But, looking at it I would say that the bit was either blunt, the wrong type or the feed speed was too slow and it has melted/ welded the cut rather than cutting cleanly and clearing the chips.
A 1mm endmill with 2 flutes leaves little room for clearing waste maybe try a single.
What does the endmill look like now, does it have aluminium stuck to it ?
I am sure someone will be along with a comprehensive answer shortly.
Ollie
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