Watching a guy in Phoenix run a 5-axis job with no coolant changed my whole setup.
He was cutting aluminum at 12,000 rpm and just used a strong air blast to clear chips. I always thought you needed flood coolant for anything over 8,000, but his finish was perfect. Now I run my smaller parts dry with a high-pressure air gun and save a huge mess. Anyone else try switching from flood to air for certain materials?
Dude, that's a game changer. I switched to air for dry aluminum milling and it's all about the chip evacuation. You gotta get a GOOD vortex tube on your air line to keep the tool and part from getting too hot.
Switched to air on my little benchtop mill for 6061 and it was a total mess saver. The key was getting a proper air nozzle right up close to the cut. You ever notice how much quieter it is without the coolant pump screaming?