Aluminum feed and speed question

On the larger holes does your operation have “stock to leave” checked?

I would recommend against plunging, ramping down into the stock is generally less violent for the cutter and helps get the chips out more effectively.

I only see a boring operation in that nc file, what are you using for the larger holes? An adaptive clear followed by a contour works well for the larger holes and the slots.

I had more success with single flute cutters in Aluminium, but you’ve chosen a decent hard alloy which does machine. Air blast or suction to get the chips out of the way are table stakes for getting a decent result.

How are you planning to hold the piece? For this I’d suggest the Scotch Blue 2090 tape and superglue, works really well. Clean the piece first with Isopropanol (which is also great at getting tape goo off later).

EDIT - I realised it might not be obvious, it is quite common practice to run a ‘roughing’ cut first, using a strategy like an adaptive clear set to have, say 0.5mm stock to leave, then to come back and do ‘finishing’ passes at a much lighter cut, say, 0.25mm stepover to give a clean finish.