Milling deep into 6062 T6

[Muzzer]

As I understand it, going up in diameter but trying to keep the feed rate, DOC etc the same will result in a higher surface speed and spindle power. That may not be an issue depending on your machine if you ensure the chips are cleared successfully - that's what has cost me most cutters over the years. Air blast or high flow coolant is the best solution. Make sure you use uncoated cutters and ideally polished / honed at that. Max surface speed isn't usually limited by the cutter but by the machine spindle speed or spindle power.

Generally I use 10mm diameter carbide cutters or larger indexable tools. Bigger carbide cutters cost a lot more per crash! I often use my 50mm indexable shell mill with APMT / APGT inserts to the full 10mm DOC - these are often only used to take skim cuts but are in fact great for roughing.

The only time I use less than 10mm is when the slot or internal radius requires a smaller diameter cutter.