When cutting aluminum on a router, you have to rely on the chip to remove the heat from the cut zone. A single flute cutter, like this Onsrud O-flute gives a nice fat chip that will allow you to get a clean cut without using coolant. For this 1/4" bit, start off at 18,500 rpm on your spindle, 85 inches/min (2200 mm/min) on your feed rate and 3-4mm on your DOC.
Source: thousands of sheets of aluminum through my router.