Any "Best Practice" Recommendations for clearing chips and feed/speed when cutting Aluminum??

Well, tonight I switched from cutting wood to machining 6061 aluminum with
my Sherline Mill using a 1/8" end Mill to Mill a part 1" x 1.6" by .25"

It was an education to say the least. In the process of documenting the
results, I arrived at some questions:

When I was practicing on plastic and wood, I ran the ShopVac with the
intake nozzle next to the cutter. This way, it was a superbly clean
process.

When cutting aluminum, I used WD40 From time to time to lubricate the
cutter. I noticed that the WD40 label says "Highly Flammable - propane." I
decided that I would not use the ShopVac and the WD40 at the same time for
fear of starting a fire inside my ShopVac and making my ShopVac a flame
throwing jet engine. (Am I correct in this concern)

Since I was no longer using the ShopVac I now had a micro chip problem.
This was further complicated by the WD40 (used in moderation) and resulted
in an aluminum "Slurry" surrounding the cutter and resting on top of the
part.

No problem, I thought. I used an acid brush to brush away the debris -
still wishing I could run my ShopVac.

Well, combine the above with the lessons I learned about climb vs
conventional milling as well as and feed/speed rates, I have probably
broken many rules tonight not to mention possibly destroying my cutter. At
least I am learning and having fun while making chips.

So, now that I have shared the gory details, I will ask for
feedback/correction:

1. Any ideas on the removal of chips

2. Any ideas on the lubrication of the cutter (It's an 1/8" end mill)

3. I experimented with feed rates and speeds as I was encouraged to do. I
came up with 2500 rpm, 5-10" ipm on XY and 1 ipm on Z seemed to work. I
would welcome some recommended rates for my sample part

Spindle Speed?
Feed Rate XY?
Feed Rate Z?

This is a learning adventure for me. I'm open to all kinds of feedback so
fire away :-)

Thanks. I cant wait to check my email in the AM to see what kind of
responses I get....


Eric Mack
glee@...


P.S. I am documenting my adventure to try and write a tutorial to help some
future lost soul do this. For now, I return to wood and plastic for
practice until I master the speed/feed stuff.