Aluminium cutting

[Jonathan]

Your chipload is too high. For single flute tools, these are roughly the settings I use for cutting aluminium:

Ø1/8", 24000rpm, 500mm/min
Ø4mm, 18000rpm, 600mm/min
Ø6mm, 12500rpm, 600mm/min
Ø8mm, 9600rpm, 600-700mm/min

...then tweak the rpm until it 'sounds right'. That should get you close enough. With limited coolant I'd be inclined to lower the rpm and feedrate proportionately - soo keep the same chipload but run slower.

Well take this with a pinch of salt but Gwizard tells me that at 15000rpm 1.4 doc 279 mm/min plunge 276 mm/min and 24000 rpm 446 mm/min.
I am not an expert by any means on using the calculator so please wait for another opinion. ..Clive

Last time I checked, all Gwizard does to calculate the plunge feedrate is set it to the linear feedrate divided by the number of flutes - so for a single flute cutter it's the same. It's much kinder on the spindle not to ramp instead of plunge, or at least plunge a bit more slowly.

Here's a video of my machine cutting with the same tool (@2:14):