"Robin S." wrote in message
...
I've heard it said that machining aluminum is like machining wood.

Ok, that's not entirely accurate, but...

I'd be inclined to cram a roughing endmill through there and take it all
out
in one pass, letting the slug drop through. I'd do the same with 3/4" tool
steel given a capable machine. While you won't need a hacksaw, your arms
will probably be pretty tired by the end of the run.

How large of an internal radius (in the corners) can the application
tolerate? Obviously, the larger the rad, the larger the cutter, the
heavier
the cut. You'll want less flutes as opposed to more flutes (for chip
clearance). LOTS of coolant. Your table will probably be overflowing by
the
time you've finished a couple of pieces.

If your machine has a DRO, you'll have an easy time. If not, I'd be
inclined
to set up a bunch of indicators or stops to make the job go quickly. 24pcs
is enough to justify a longer setup, IMHO.

Good luck and don't forget the coolant!

Regards,

Robin


Robin,

Suggest dont confuse him further, looks to me he may already be already in
deep trouble here as it is.

--

SVL