I get to make a boatload of small accurate parts from 6061 Al, mostly 1/2" stock. I sooo like Aluminum! I bought a bunch of different size stock bars from McMaster, they deliver the SAME day, how cool is that! But, squaring up my sawed pieces with very light cuts in the BP has me a bit confused as to how I'm getting tiny amounts of swarf that are 'kinda welded on the cut surface. It seems to scrape off easily. I'm using the side of a new 3/4" HSS end mill without lube and clamping the pieces in the vise and cranking the "Y" handle.
Years ago I bought a large amount of Al drops that were some kind of high-strength aircraft alloy, I don't know what it is but it machines beautifully and no swarfy-sticky issue. I NEVER though I'd be asking a speed/feed/lube question but I'm curious as to how I can do this better. Is the 6061 just softer/gummier? I have 54 more parts to make and as much as I like doing the work I hate wasting time scraping the parts. I hate cleaning lube off of them too. Actually, I think I'd much rather just draw the stuff and have it magically appear on my desk.