A 16 mm three-flute aluminum mill at the tool card's rpm sounds smooth and grows a cap of aluminum on the edge after a few minutes. The finish goes dull, then the size moves. Coolant is flood, not through-tool.
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Built-up edge on 6061 at a 'correct' speed is often the edge rubbing because the chip is too thin or the coolant is not reaching the cut. Raise the feed per tooth so the tool cuts a real chip, and aim a closer nozzle before you drop the rpm.
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A polished flute and a sharp uncoated or ZrN edge sheds 6061 better than a worn general-purpose coating. Once a cap has started, the edge is already welding. Change or clean the tool. Do not keep running it.
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If the cap returns at a healthy chip load, the flood is mostly hitting the holder. Through-tool or a well-aimed jet changes this more than another percent of concentration.
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