Aluminum is the most machinable common metal — soft, light and fast-cutting, ideal for high-speed machining with high spindle speeds, high rapids and light, fast passes. The main challenges are chip evacuation (it makes lots of chips fast) and built-up edge on gummier grades, both solved with sharp polished tools, good coolant/air and high RPM.
The machine that shines here is a fast-spindle VMC or router built for speed and chip clearing. See aluminum and high-speed machining, and value machines at The Machine Blue Book.
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