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Originally Posted by Cathar
You do a depth pass of 2.0mm with a 1.0mm end-mill in copper? Sounds pretty ambitious to me. Not saying that it can't be done, but typically faster to do 0.5mm depth cuts per pass and feed at a higher rate, or at least that's what my machinists told me. Had problems enough with the end-mills snapping as it was with 0.5mm depth passes. One end-mill bit lasted about 15-20 blocks.
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I don't with my little POS mill. If I have a 1mm endmill I will make .5mm passes at 1IPM at 2800RPM. It depends on the mill of course. .5mm passes is the way to go for overall speed. Modern mills running at 15,000RPM can get insane IPM feed rates in copper. I can't see it taking more than 30minutes to make the entire block on a good mill with a tool changer.
I think I left out a channel in my previous calculations. With the block in hand I see 8 channels. They average 1.3125" in lenght and 4mm deep. So 1.3125 x 8 = 10.5". 10.5 x 8 passes is 84". 84" / 5IPM = 16.8 minutes on a average CNC mill. That is not counting the move to the next channel but that should be a rapid move. Still no where near 30 minutes and anything resembling a modern mill should be at least twice a fast.
EDIT: Forgot to mention your right about the .5mm passes at a higher feed rate.