I think I overcompensated speeding things up when people told me I could go faster than my initial 250mm/min cuts on my C-beam based CNC 
Videos below are at:
1mm DOC
10mm/min plunge
750mm/min feedrate
15k RPM on the spindle
4mm single flute carbide endmill
Unfortunately the endmill flute filled up and solidified with aluminum on the second to last outer profile cut. I was able to save the part but the edge finish is very bad. Time to go back to the drawing board and find a happier medium.
But it sure was fun watching the machine absolutely fly through that 1/4 6061 aluminum plate. 
Thats exactly what onsrud rates their cutters at chipload wise though. Maybe back it down a bit or make sure you clear your chips. Recutting chips is one of the fastest ways to kill your cutters.
@Joe_Spanier ​ yeah, I was too busy taking video to clean chips 
I will be building a cyclone seperator and vacuum chip shoe over the next few days. I think I could go that fast no problem… Maybe just a smaller depth of cut than 1mm. I will try a smaller test piece next time. The holes looked good, it was just the profile cut that looked smeared. Plus I am cutting with zero coolant. Perhaps a mister nozzle would help keep the speeds up.
@Eclsnowman I’ve been wanting to setup a mister on my machine but am afraid of the effects on the mdf
is your machine all MDF or just the spoil board?
@Joe_Spanier Spoil board. I’ve toyed with the idea if coating it, but eventually the surface will be spoiled… haha. Then need to be resurfaced
I usually throw another board on to be soaked. I like CDX for this as its not effected near as quickly.
@Eclsnowman you’ve been busy my friend! Love to see this thing on the other side of a video, really cool!
Chip removal, recall when we were speaking about the step-over in CamBam, stock setting at .4mm, bump to .5 and adjust cut width. That should resolve that issue of build up. Watch your interfaces when doing multiple pieces on one sheet.
Chip load, you look amazing at the holes. I’ve yet to see another DIY CNC dive like that! On the profile cut, dive deeper per pass or speed up the velocity or slow the spindle RPM. To get that beautiful nice cut simply takes practice in tuning all three of the above variables. Your looking for squarish chips ~1mm x 1mm on this single flute 4mm, there should be a ton of them per pass, but the relief and the upcut endmill should keep everything out of the way. You will be moving old chips but the new chips and air should evacuate enough not to have a build up. I always cut dry, never blow out the chip load, and take endmills beyond where they should be… In fact I remember thinking I wanted to cut your plates with a dull endmill just for this conversation. The endmill I used for yours wouldn’t cut my finger dragging it down the cut edge. Sharper would have left an even shinier cut.
These cuts look amazing for your first rounds, you’ve done an amazing job.
What kind of tool life are you seeing @Brandon_Satterfield
@Joe_Spanier a 4’x 8’ sheet of 1/4" aluminum after I’m done there’s not a whole piece one could put his palm on.
