Is it better to use a 1/8 or 1/16 endmill when milling aluminum? Both bits are double flute? I have an image of what I’m trying to do below. The shape is going to be milled of 1/4" 6061 aluminum. The yellow areas will be pocket holes 1mm deep, the larger yellow area at bottom will be 4.7mm deep. The blue holes will be tapped with a thread mill and 5.35 deep. All other holes will be all the way thru.
My thoughts, use 1/8 endmill to cut main shape and pocket holes, and use 1/16 endmill for the drill holes. Or should I just use the 1/16 endmill to cut everything?
Am I better off going with trochoidal milling for this? And would anyone have any recommendations for settings? What would be a good setting for the holding tabs?
Going from mdf to aluminum, should I not use the same endmill bit? A old time woodworker told me with router bits that mdf dulls them out well, not sure if it’s true or applies to endmills.