Milling aluminum??

[Karch]

WD40 the heck out of the bit while you work too. Aluminum gets gummy when it's being milled. The WD40 will cause the metal to sling off the bit while it turns. Use this pretty much whever working with aluminum. Drilling, sawing, milling. No need on a lathe. Do not use WD40 when messing with anything other than aluminum. It will not work with steel.

I worked at an aerospace machine shop for a few years, and I agree.
Tap Magic is also a great product, but WD40 gets the job done for less coin.

[astroracer]

I used a speed controller on my router when I made the step plates for my truck. Did a few test cuts to dial in the rpms and it worked very well.
I am surprised your drill press didn't drop out the chuck due to vibration. A mill uses a collet that is held in with a long bolt through the spindle. Most drill presses rely only on the taper and pressure from drilling to keep the chuck in the collet. I think you dodged a bullet with this one...
Mark

[BADVELLE]

Thanks for the heads up Mark, you are right I did dodge a bullet.

[Modo Innovations]

Another home remedy for lubrication while machining, sawing or drilling aluminum is to use a bar of hand soap. Ivory works well, I have a bar out in the shop for a stand by.

WD 40 works very well and is an easy clean up. The Tap Magic, for me anyway, stinks and if you get it on you, you will smell it all day long.

[astroracer]

There are two formulations for Tap Magic. One is for ferrous and the other is for non-ferrous. If you are trying to use the ferrous formula on aluminum it will just gum up. When used correctly both formulas work very well.
Mark

[BADVELLE]

Another home remedy for lubrication while machining, sawing or drilling aluminum is to use a bar of hand soap. Ivory works well, I have a bar out in the shop for a stand by.

WD 40 works very well and is an easy clean up. The Tap Magic, for me anyway, stinks and if you get it on you, you will smell it all day long.

I have always used bees wax on tools like my files when working on aluminum.