I finished hand drawing the fin pattern, by hand, which took me a few hours. I'll scan and post it tmo.
The twin blade idea would actually save some time, but I understand that it's hard to see the necessity without this drawing.
Fixittt, I still need to know what size blade (20, 25 or 32mm) you need, to make a 5mm deep cut. The collateral damage to the other fins depends on the size of this blade. Either way, it looks like finishing this thing with a 1 mm endmill is the best approach. I can still minimize the use of this small endmill, but it looks like a requirement, for tiny, tiny little finishing touches.
In case it's not clear, I suggest cutting the 5mm channels, as much as the round saw blade can be used, without cutting into other channels, then cutting the rest of the channels with a 1 mm endmill. If you're still up to doing this, I would of course get these cutting bits (blades, endmills) to you. I am still offering to compensate you, if you want to make this block.
I still don't know what level of precicion you're capable of. So far, we have a 1.5 mm wide fin, and a 1.0 mm wide channel. The angle of the cuts is full circle, in 11.25 degree steps, with off-center offsets of 1/2 the fin width, or +/- 0.75 mm. Does this fall within your level of precision? What's your margin of error, or tolerance?
From looking closely at the design, I've observed that it's not optimized for uniform flow, but that as long as the nozzle isn't smaller than 3/8 inch, it should still function nicely. I say 3/8 because that's the point where the tip of fin set#3 is visible from a 3/8 opening, allowing the coolant to seperate into 16 channels pretty much equally. The flow should otherwise "theoretically" split in a 1.5 to 1 ratio, at the tip of fin set #4.
It looks like I'd also need a set of "drop-in" nozzles, so that I can run tests at different flow rates. I'll post specs later.
I agree that the "turntable" would be pretty rough. Definitely, the block would have had to be bolted to this table: I'm not that silly! Judging from the sheer density of the copper, and with the little (not nil) experience I have cutting metals, I wouldn't trust it to stay still without a sturdy hold-down.
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