Tell us about yourself!
I have been doing some aluminum facing this weekend using feeds of 22 in/min with DOC .008" using 1 flute Onsrud bit. Probably could push it further.
I performed several tests with different bits, feeds and speed. Both 1/4" and 1/8" end mills run pretty good, but 1/4" run the best. I run 1 flute Onsrud and the cheaper Niagara Cutter 2 flutes (they work about as well). The most I can get out of a bit without chatter is about .008" stepdown and 20 in/min feed rate. All of my parts machined in the videos were either .002" stepdown or .004". I use Autodesk Fusion 360 (free!) Cad/Cam and it helps keep chatter down by setting ramp rates and such. Another thing is the runout is a little much on the spindle (.0025"), but I was able to make some improvements to get it down to .001". It is still a lot and will impact chatter.
I finished my build and ran some aluminum. Runs slow, but does a great job! Here are some links for my setup:https://youtu.be/cRcb9yR76Jg https://youtu.be/oDyFuzOAQ8A