Phuzun: I don't quite get what you mean.

Hara: I don't know, but I'll certainly try. I don't have the knowledge, nor the tools to accurately optimize the design, so I'll do it the old fashion way: make multiple iterations and/or mods.

GTA: I'm still negotiating with FakeSnake for a build, but I've also asked JayDee116 if he was interested. Maybe I just burned my bridges here :shrug:

Utabintarbo: The only progress I can't report (but will anyways) is that I was successful in calculating the pressure drop for LiquidRulez's top secret block. Since I can do it for him, it means I can also do it for myself ;) . I have yet to run the flow test, by drilling 4 * 1/16 holes in a cap, and seeing how the pump will behave. Since I now have a flowmeter, I'll be able to get a (relatively) accurate reading, except for the pressure drop of the meter itself :( which is still unknown, because the flowmeter manufacturer has yet to provide me with the pressure drop curve :rolleyes:

I haven't spent any time finishing the res (for the block), but the new/revised airtrap is almost complete. I'll be able to test that, hopefully this weekend.

On related topics, also under construction are:


the HDD block

the (revised) airtrap

the PSU array

Also, I received the sample of Silkolene ProCCA, thanks to Bruce, from www.CoolTechnica.com, one of our sponsors. (Thanks Bruce!)

I also ordered the heatercore, #2-304. Pic can be found in here.

Some location/mount details can be found in this thread.

flowmeter details

Yes, it is possable on a 3 axis mill. 1...the easiest is with a form cutter..a radius tool. The other way is a bit tougher but if you have a ball-nosed endmill then you can do it with existing equiptment. What you do is litterally "generate" the radis in, by using the ball em to go around in a circle at a certain depth, then step in ( or out ) & move your Z axis down ( or up ). After about 100 passes, you are done. Tends to make lengthy programs, but if you need it/are interested, PM me.

Or, just for fun, you could generate it as 1 continuous spiral from top to bottom using a ballnose. I think I might want to try that...

Bob

bahhh...I got too much time on my hands
http://home.attbi.com/~jmcook3/Image1.jpg
That is very close to what the final toolpath would look like.

Very nice. What software did you use?

Fellow CAD/CNC geek, :D
Bob

We got Mastercam V9.1 at work, its the best for toolpaths. I prefer to model things up in CadKey though.

I have been wading thru the entirity of this thread for about 2 days solid, following all links too :(

I just have to say - AWESOME work guys.
Just one thing to contribute regarding the air trap mechanism.

Why?

Would this way not be easier using a standard reservoir??

Excuse my poor PSP skills.

http://users.firenet.uk.com/flymo3/passthrough.png



Keep up the good work
Flymo

Welcome to ProCooling!

Did you miss a page? ;)

There is a res, but not like what you've drawn up. There is also a seperate airtrap, which is also linked (oh my, what patience you have!)

Your idea is good, but there's a serious space constraint, where the width of the case is only 8 inches (typical?).

I may very well go that way later, but for now, it's good enough (as Bill would say).

I'd love to simplify the current res design, but it would involve working with raw materials, instead of existing PVC fittings, which are actually a charm to work with, but I just don't have all my tools together (cousin: where's my Dremel?!? Dad, I need that scroll saw and sander!!!).

Right now, I'm concentrating on the PSU array, sorry. I started in a new job today, and got a new PC all to myself :D , so SW2K3 is going up very shortly.

I also might add a smoother exit to the fin pattern, just like I've been recommending to all the new blocks that called for it.

Ya'll check out Zymrgy's design, here: it's the best I've seen in a long time.

Bump for an update!

Any progress on mfg.?

Bump for an update!

Any progress on mfg.?


Edit: I don't know how THAT happened!:eek:

Sorry, no.

I'm concentrating on getting income right now ;)

Just had an interview at the local hospital, which just expanded with a 7 story high building. They'll need me and my IT skills, but only in three weeks.

Otherwise I've got dibs on some contract work, assisting a project manager, in two weeks.

Fakesnake disappeared, or is busy on extensive house renovations. In the mean time, I'm helping NordicHardware round up a bunch of waterblocks. I think I'll go with JayDee116, for the making. I've got the copper, sitting right here, but I still have to order the endmills.


I'm thinking about boosting the flow rate, using both my Little Giant 2-MDQ-SC, and my new Johnson pump. If it works well, I might swap the LG for another Johnson pump, and keep it all compact.

I have the Silkolene, thanks to Bruce from www.cooltechnica.com .

www.leakycar.com is trying to source a blower that'll fit in my case. I requested something that's up to 8 inches in diameter, and no more than 8 inches thick.

So if I boost the flow rate, I'll definitely have to get another heatercore, and run both in parallel, since I'd be reaching a point where the flow rate is detrimental to their performance. It'll all be shrouded using a custom made fiberglass and resin housing.

Otherwise, I'm still waiting on Yo_Duh's idea for securing the PSUs from feedback, in the array.

I'm still trying to work out the inlet/outlet, for the HDD block.


Oh, did I mention the wife and I are buying a house?!?

I am trying to figure out how to make a tool path .dxf my mill will except. Once that is done it should be just a matter of tuning the feed rates. I have to make 3 different .dxf's. One for the O ring groove, one for the outer circular channel and one for the mini channels. My mill doesn't seem except tool stops.

johnson pumps, eh?

i'll shortly be using the CM30 i found at a local surplus house.
http://members.arstechnica.com/subsc...10_30-C090.gif

3.5m head is really nice for its compact size, but it's a little on the noisy side. Kind of a high pitched whine. I'm also a little concerned about RF noise the brushes might introduce into the system through the 12v line.

But you didn't say what model you're using, so this could all be rather irrelevant. Care to elaborate?

Hello guys Noob here hehe <--- to the forum at least

First let me say that I'm really impressed by the technical Knowledge in the room. I didn't think anyone took cooling as seriously as I do. I'm tired of seeing all these UGLY! homemade WBs out of tin cans and shite. To the point I've looked at some of your threads and like what I see. I really like the one hose idea in this thread and plan on using it on my first water cooling project. As for the WB I'll be using.. I haven't made it yet but the idea is growing. Here is where I'll need some technical advice, and a tap into the maximum tolerances of copper.

For now I'll just ask what is the thinnest fin that can hold up to the turbulance created by the average water cooling pump without breaking or bending too much?

I have a lead on a laser engraving machine(I think i can get some free time:cool: ) I was told it wont be easy but copper CAN be cut with it (untested as of yet)

I think you have an idea of where I'm goin here:) Micro fin WB the best of both worlds

Thanx for hearing me!

I think that wouldn't be a problem since the flow would be parallel to the fins. I'd say up to 0.3mm would be feasible. ;)
No point in going smaller than 0.5mm fins i'd say though.

I run a laser engraver at work. It is 80watt with a 100watt tube and it will not even scratch the surface on any metal. You will need around 500+watts to remove metal I would think. If you have access to a laser that can do that then let us know. That is certainly a option I have been considering in mass producing blocks but I can't find anyone locally with a laser strong enough to remove copper. This would be ideal for making Bens Radius!

Ben, why don't you go to an experienced professional machinist with a Big Ass 3 axis cnc? Given enough rpm, 4mm coated carbide cutters, injected coolant and the right feed rates your radius could be milled in minutes. Really. :)

Everything has a price though.

That's the problem!

I am not saying I don't want to attemp to make your block, but it may be worth getting Zymrgy to try and make it. He seems to have forgotten more about milling than I will probably ever know and he might have access to a mill that make your block as perfect as it can be. Or maybe he can take your design and make the tool path dxf's? I am having no luck at that. I need a tool path dxf for the O ring groove, the outer circle, the inner channels AND the outriggers. It can be in one drawing as long as it is a ACAD style .dxf that I can edit. I can't do anything with that that solids works file as I can't get it into .dxf form. :(

Scratch my last post. The drawings are in .dxf form (thanks to Zymrgy) and seems to be editable in ACAD. I finally got a top view so drawing the tool paths should be easy. I got a simulation program with my mill which shows a preview of what ever it is cutting as it would be happening on the mill so I should be able to get it all setup by the time i get the mill itself set back up. Only issue I may have is lack of RPM. My mill tops out at 2,800RPM so I will have to severly drop the feed rate. I hope I can get it to run slow enough. If not i will buy the 10,000RPM pully from Sherline that is made for the mill. :)

just read every post, and i've just realized that this is the 500th post! yay!

jaydee, what kind of controller is on the machine that you got? Be as specific as possable as to the make/model of it. I might be able to help you out in getting the thing to run with a more conventional format....that is g-code.

It is a tiny desktop mill. It is nothing like anything industrial. The stepper motor controller is run by the computer itself instead of the job loading to the controller and the controller handling the job. Which is kinda cool actually as it shows on the computer screen exactly what it is doing on the mill and you can run it without the mill on.

Here is the G-Code commands it supports and doesn't support.
http://www.acumotion.com/gcode.shtml As you will see it is very limited. The software has a .dxf to G code converter which works well as long as it is a tool path .dxf.

Let me know the cost: I'll make a contribution to that.

Thanks for your patience!

If you guys can deal with APT, and have a post-processor, I can hook you up quick.

Alternatively, I could take a shot at some G-code for jaydee's machine. I will look into that tomorrow.

Bob

Yeah if someone less "ignorant" than I about G-code can take the list I posted above and make some code it would probably be better than the software converter it came with, it does seem to work alright, but it certainly isn't optimal. I would ask though that the code be seperate for each type of tool needed and just set it up for one pass on each section. I will manually set the depth each pass as I have no clue how deep I will be able to go on each pass untill I try it.

I was just looking at it....I could program the thing easily using the G-codes from your link. You might have to manually edit the program, but I can help you out with that also. You are limited on you rpm & stuff....but I can make a huge program...light depth of cuts, slow feed rates, ect. the thing might take 8 hous to run....but then its in your garage...just get the thing going...play a round of golf...come back, check on it..go to bed...it the morning, viola. This ould only be for the detailed center area...obvioulsy for the holes & stuff you would have to be there to set up tools & such.

Yeah the center area is all I really need, the other stuff is easy. I can only run the mill for 30-45 minutes at a time as the motor is a high tourque DC motor with no self cooling. They only recommend continuous use for that amount of time. So if you want to make just a one pass set of code (which it would probably be 45 minutes a pass) it lets me edit it after each pass as it has a G-Code window and shows all the steps as it is happening. I just have to change the depth of the cut and hit go after each pass.

jaydee...do you have ICQ....mine is 72122748

Yeah I just signed up actually. 209088941 is the number they gave me. I am off for the night though. Should be back online after work tomorrow.