Please download a latest update 1.161 There was an issue with metric machine limits in the previous update. But i am not sure it affected you. Hmm... could you attach some screenshots? This is what i am getting in HSMAdvisor:

Also see the first attached image. Perhaps your machine definition is limiting things for you? Edit: Make sure to use some sort of lubrication as aluminum is very sticky.

Sure, would love to learn why my mistake is (which is far more likely than a code issue!). Attached are my two screenshots taken just now. I think I have got a little closer. After you mentioned it I went back in to the machine definition and re-saved it with a new name. When I set the max feed rate to 2000mm/min, all in metric, (78.74in/min), I go back to the main sheet and it warns me that the max feed rate is exceeded and the RPM has been limited to match max feed rate, but that's now set to 78.74mm/min. Looks like it/me might have some confusion with the conversion of machine limit.

Please download and install the latest update. Also go to Edit Machine and make sure "Calculations Stick to RPM Values from the table below" is off. That option forces your calculations to math the closest table value. See the attached screenshot:

I updated and restarted HSMA, re-checked/corrected the machine info and hit save. Back to the main screen changed the material then changed it back (in case it was a variable update issue) but I still get the same results. I expanded the panels a bit to show the rest.

Ah I see it now. You have Custom Cutting speed set up in your Manufacturer Speeds and Feeds panel. That is an override that people usually use to set starting speeds and feeds supplied by the manufacturer. Click on "Speed" label to set it to deafult. In the future you should use Reset button, Located on Tool Data panel to reset every parameter to default when you see something does not make sense.