I have a new manual crank mini mill. I have been trying to figure out what RPM I should run the machine at for the type of applications we commonly use. I understand that metal hardness, thickness and diameter of cutting mill affect RPM.

My first task is to mill a slot in a ferrule stack of 1 layer of .20" 5160, 1 layer of .0625" stainless and three layers of .01" copper. I will be using a .125" diameter end flute.

Should I use the end flute to predrill holes and then clean out webbing? Can I drill the holes with the end mill? Or do I predrill with a drill bit and then put in my end mill?

Can I mill these as a block if they are super glued and have two alignment pins and have square sides to be clamped in vise?

Or mill them separately and what RPM's should I use?

Here's a tutorial that Karl did... should answer most of your questions  

http://tradgang.com/cgi-bin/ultimatebb.cgi?ubb=get_topic;f=110;t=002754

Thanks Jeremy and also to Karl.