Drilling holes in 1/8" Aluminum

[BPM]

New Shopbot owner here (PRSAlpha 60x144)(ATC)(Vacuum)(HSD 5HP spindle)

I have an on-going product that is milled out of aluminum - 2.5"x4" aluminum name plates - 1/8" thick. The end product will be milled/engraved in a VMC (metal vertical mill - such as a HAAS or Fadal).

I receive the aluminum stock in 12'(ft) lengths -- 2.5" Bar Stock, 1/8" thick - 12 feet long (Aluminum 6061 or similar).

Each name plate has 4 holes - drilled and countersunk for a #10-24 machine screws.

I'm thinking it might be easier to do the drilling on the Shopbot -- i.e. lay the 12'(ft) barstock on the vacuum table -- and drill all the holes -- in a 12'(ft) length - there would be 32 finished plates * 4 holes = 128 holes.

I'm definitely not excited about running any type of liquid lubrication on the shopbot...

So.. finally to my question.... do you think I can drill these holes on the shopbot without lubrication? 3/16" dia holes - counter sunk for a #10 screw.

FYI - after the holes are drilled - I'll chop the 12'(ft) length into 18" pieces which would then be fastened to the machining plate in the Fadal VMC (where the engraving/milling/cut outs are done).

Thanks in advance for your review and post. As soon as I learn enough to be dangerous -- I'll start posting! :D

Also.. if the drilling is doable -- how would you make the cuts? (cut/chop the 12'(ft) length into 18" pieces) what bit would you use... would you leave a 64th... etc etc

[Brady Watson]

No lube required if you use a Harvey or Onsrud 1/8" dia single spiral-O bit. You NEVER drill aluminum with anything other than an electric drill. If you pull your spindle off, you can throw a Milwaukee drill onto it & you are good to go with a drill bit & drilling strategy...

However, you can do an inside profile cut on those 3/16" holes with an 1/8" bit. You NEVER plunge straight down when profiling. Choose a spiral/helical ramp when you calculate your toolpath. I would go 1/32 per pass, 1/16" max if the tool can handle it. Then profile as needed. Zero coolant needed.

Go make some money...:D

-B