I recently tried cutting profiles in aluminum sheet on our PRS standard w/ HSD spindle. I'm getting a burr along both sides of the cut. I played with my feeds and speeds until I broke a bit. Here are my settings:

material: .050 3003-H14 aluminum [spray glued to spoil board for hold-down]
Bit: 3/16" single flue

6239_3_.jpg

10,000 rpm
30 IPM
.032 pass depth [2 passes]

calculated chip load: .003

climb-cut
ramped into material

Here's the result:
AL test.jpg

Any thoughts on how to eliminate the burr?