I want to encourage you to start your company. I had the oportunity in my career to be out of work in the past. I refused employment in many machine shop companies that were being run from home kitchens, bedrooms, and basements. Ten years later I found myself out of work again. To my amazement...
The main problem is that the Aluminum is welding itself to the tool cutting edge. With some Aluminum Alloys it is a constant problem. Every few minutes take a razor blade and scrape the Aluminum from your cutting tool. You will find that you can work faster and hold closer tolerances.
Stress Relief seems to bring with it the problem of warpage and bending of shafts. You may have to hand run a Die over the threads to straighten and clear oxides from the thread root diameter.
