Finished the Flip Side

I was able to run the Taig CNC today to finish cut the motor side of my trial heat-sink. It has a few flaws here and there but fairly minor. They were caused by broken milling bits and having to start over several times.

Actually this is “good enough” for actual use if that term is acceptable. It is perfectly functional and ready for use.

I have four more to make so I will be well practiced by the time I do the last one. The time on this side to cut all the fins and a finish pass on the inside took almost five hours.

That doesn’t include the 1/4″ end mill time for cutting the center recess and the big hole. That is about 60 minutes more to do both sides.

The fact is it takes a LOOONG day to make one of these. OK for personal use but hardly worth doing for production. That is the time cost in making what is a fully machined prototype (or five). For volume production this would be best be a casting and then the only machining would be to set the desired inside thickness and create the flat heat sink contact area which is seen on this side.

All the fins on both sides have been cut using only one 3/32″ 2 flute solid carbide end mill. Looking at its cutting end and how it was performing when this side was done, I would say it still has a lot of linear feet left to travel.

BTW, the Taig mill is performing wonderfully spinning for many continuous hours at 10,600 RPM at the spindle; Which I must add, doesn’t even get warm.