Well, I tried something new today.
As part of the upgrade I needed to cut access holes into the welded steel frame. The steel is low carbon steel and not all that thick. It should be a piece of cake, but these routers are not machining centers and not really designed to cut steel.
So the cutting parameters
1) I just happened to have - 5 flute SGS TiAln coated end mills.
2) I ran at 8000 RPM
3) I ran about 20 IPM
4) I used a spiral ramp infeed at .002 DOC
5) I used Tap Magic cutting fluid
No problem at all.
The hole is 1" wide x 3" long.
I will be bolting the 8020 with 2 - 1/2-20 High strength bolts. I am making special washers that are 1/4 thick 1" wide and 3" long. Each washer will have 2 holes for the bolts. The bolts will go through the 3" square 8020 extrusion with the special washers and very very very tight.
All of this so I can make CNC dovetail joints. I have seen some really cool joints out there. I will not be bound to the restrictions of a template.