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Those long chips created by cutting aluminum? They can build up around your tooling and cause all kinds of problems: sticky buildup, increasing heat, and more.

In any case, keep checking those chips to make sure they’re getting cleared out. Meanwhile, note the color of the chips, which may indicate various problems:

Cutting aluminum also creates long chips, so you want tooling that supports good chip clearance. Choose tools with a maximum of three flutes.

Some properties have legacy aliases, like FREEZES in place of STOPS. Additionally, keysounded SSC charts use a NOTES2 property for note data instead of the usual NOTES. StepMania looks for these aliases in the absence of the regular property name.

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Considering that aluminum can melt during cutting and cause broken tools, set your machining speeds and feeds carefully.

Also, pay attention to the size of your chips. This is largely determined by your speeds and feeds. You want to see thinner chips that don’t look like shavings. Take this information and fine fine-tune your speeds and feeds off of it.

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It’s very ductile stuff, meaning that it tends to stretch when cut (instead of just breaking into small bits). But, the key material property to remember about aluminum is that it has a very low melting point, and when it does melt, it sticks to the cutting edge of your tooling.

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StepMania uses this information to determine how to display the simfile in-game. Later in the file you’ll see timing data, which determines how to keep simfile and audio synchronized, followed by charts containing note data, which contains the input sequence for the player to perform. Charts are typically written by humans to follow the rhythm of the song.

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One more thing about machining aluminum: the high-quality milling machine you use is likely to need 3-phase electricity. So what do you do if your machine shop has the typical residential single-phase power service?

Depending on your machining operation, you can use flood cooling—continuously applying the coolant—or intermittent mist cooling.

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Even if you don’t need the rich functionality of the supplementary modules and packages, the top-level simfile module and the SMSimfile and SSCSimfile classes its functions return are thoroughly tested and offer simple, format-agnostic APIs. While a bespoke regular expression might be sufficient to parse the majority of simfiles, the simfile library is designed to handle any simfile that StepMania accepts, with escape hatches for error conditions nearly everywhere an exception can be thrown.

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To prevent these issues, you need carbide-cutting tools that can handle high RPMs while maintaining a sharp edge to keep cutting right through the metal.

StepMania primarily uses two simfile formats, SM and SSC. These are the two simfile formats supported by the simfile library.

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During development of the SSC format, timing data on charts (“split timing”) was an unstable experimental feature. Modern versions of StepMania ignore timing data from these unstable versions (prior to version 0.70).

Not all simfiles are encoded in UTF-8; many older files from around the world use Windows code pages instead. StepMania tries four encodings (UTF-8 followed by three code pages) in order until one succeeds.

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As a result, your sweet spot will be pretty narrow, depending on the type of work (roughing, finishing, etc.), the cutter diameter, and the aluminum grade. Check with a feeds and speeds calculator or your tooling manufacturer’s charts.

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In addition, apply a coolant cutting fluid to the tool and the workpiece. The coolant will help dissipate heat, reduce friction, and improve chip evacuation.

Because of aluminum’s high thermal conductivity and low melt point, you need to manage several tricky issues when machining this popular material to avoid tool damage and other frustrations. Fortunately, you can follow these 5 tips for aluminum machining to maximize efficiency.

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We say it again: cutting aluminum generates a lot of heat. You’ve got to keep things cool to prevent material softening, tool wear, poor surface finish, and other issues.

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Aluminum is a soft and ductile metal used in a wide range of applications. Should be easier to machine than harder materials, right? Not so fast, my machinist friend.

Machining aluminum may be less straightforward than steel, but it’s within your grasp if you do your due diligence. Just take your time and keep all these tips in mind. And don’t hesitate to consult experienced experts if you have any questions or concerns.

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Many simfiles, even modern ones, contain formatting errors such as malformed comments and missing semicolons. StepMania handles missing semicolons at the protocol level and emits a warning for other formatting errors.

Don’t try to make deeper cuts to save some time, as this will cause tool deflection and tool breakage. Instead, doing more shallow passes will enable better chip clearance.

While the file format shown above seems simple, simfiles on the Internet vary greatly in formatting and data quality, and StepMania tries its hardest to support all of these files. As a result, there are numerous edge cases and undocumented features that complicate parsing of arbitrary simfiles. Here are some examples:

Be sure to keep clearing your chips. That 3-flute maximum on the cutter will help with chip removal. So will using a cutting fluid to help flush away chips. Or consider an air blasting system to keep things clean.

In a conventional milling operation, high spindle speeds are advised. As for feed rate, low FPM rates can create friction that harms your tools. Conversely, fast feeds can put too much stress on your equipment.

Holds and rolls are expected to have corresponding tail notes; a head note without a tail note (or vice-versa) is an error. StepMania emits a warning and treats disconnected head notes as tap notes (and discards orphaned tail notes).

Simfiles are the primary unit of game content for music game simulators like StepMania. These files contain song metadata and some number of charts (also known as “stepcharts” or “maps”) that dictate the gameplay sequence. They are accompanied by a music file and often some graphic files like banners and backgrounds.