slotting width vs depth when profiling
Recently I've had to make some very long slots in SS sheet metal to cut out some shapes (in this case, T-shaped brackets, but it could be some random shape in general). The sheet metal was .090, and I started by trying a 4flute 1/8 end mill, but I found out pretty soon that it was eating up endmills pretty fast, probably due to poor chip clearance. Cutting the profile in multiple passes didn't seem to help that much. At his time, I was using mist coolant, but maybe next time I will try flood.
This kind of got me wondering, suppose you need to cut a slot of depth "x" in order to cut out a shape, and so the width of the slot doesn't matter. What should be the diameter of the end mill you should use? It seems that if you use a bigger end mill, it's effectively a less deep slot (as a fraction of it's width) and so the chip clearance issue is less severe.