There is no way to just switch off anti aliasing for fonts that I know of.
We do exactly the same here. Design flats in Xara and then show them to clients with the caveat that they may not be *absolutely* identical when coded up. You'll have to think a suitable clause, but to be honest it's never been a problem.
Just tell them your using a Mac! They anti alias browser fonts. None of our browsers on Windows (XP or 2000) do, including IE 5, 5.5, 6+, Netscape 7 (inc the Mozilla family) or Opera 7.
best,
R
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