We do a job frequently that we cut parts multiple parts from 3/8" 6061 plate which has worked very well in the past but have never tried anything from thicker plate. I have a very similar job that requires parts from 3/4" 6061 that we've been using talon grips in vises but its slow (3 min per part) doing them one at a time.
In the photos below we use a 3/8" 3 flute and ramp 3* around the profile till full depth at .310" at 8,000 rpm and 100IPM = 9 parts in 8 minutes + we face all the plates before hand so add 2-3 minutes per cycle. I'm thinking that if we went with a 2 flute EM and heavy flood coolant then the chips would have a better chance of evacuating out of the profile pockets (.580" D) and could rig up an air blast as well if needed.
This order is for 1,000 parts so if there is a faster way I'm all ears.
In the photos below we use a 3/8" 3 flute and ramp 3* around the profile till full depth at .310" at 8,000 rpm and 100IPM = 9 parts in 8 minutes + we face all the plates before hand so add 2-3 minutes per cycle. I'm thinking that if we went with a 2 flute EM and heavy flood coolant then the chips would have a better chance of evacuating out of the profile pockets (.580" D) and could rig up an air blast as well if needed.
This order is for 1,000 parts so if there is a faster way I'm all ears.