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100% Copper GTX 580 Classified Waterblock *COMPLETED!!*

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Afterburner
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/02 13:02:33 (permalink)
Beautiful. BR for you!

 
boballee
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/02 13:34:06 (permalink)
It’s amazing what people can do with a little ingenuity, talent (and apparently in this case) patience and time! 
 
Great work, Nateman!



Alcatraz968
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/02 14:53:22 (permalink)
Nice job, wonder how cool it runs your GPU???

"I have become death, the destroyer of worlds" 
 
"Your body submit, your heart succumbs, so why does your mind continue to resist me"
nateman_doo
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/02 16:18:44 (permalink)
I just made a slightly nicer video.  I am obviously not a photographer, but you can see the plastic top I used is anything but plastic.  Its impact resistant.  I smash it repeatedly throughout the video.  It's uploading now. 
nateman_doo
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/02 16:48:06 (permalink)

nateman_doo
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/02 20:36:38 (permalink)
An evening of fluid dynamics.  Screw the computer simulations, just borrow your kids glitter
 

 

PanzerMensch
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/02 20:44:04 (permalink)
Ever kewl Nate!!
loveha
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/02 20:48:18 (permalink)
Would never have though of using glitter for a flow analysis. That bottom one is best I think when you turn it on and off.

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Gratuitous
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/03 01:46:55 (permalink)
haha, glitter:) like it! looks like it will cool very well.

“I built a castle in the swamp and it sunk. I built a second castle and it sunk too. I built a third castle and it burned down and then sunk. But the fourth castle, Ahhhh! That one stood.”
—Monty Python and the Holy Grail
 
nateman_doo
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/03 04:54:30 (permalink)
Thanks!  It defiantly has VERY high flow with no restriction at all.  Plus its VERY durable.  I was beating on it with a screwdriver and all the scuff marks came right off.  If I did that to acrylic, it would have been destroyed. 
 
I wonder why all manufacturers don't use polycarbonate?    I think its a worthwhile investment.
Gratuitous
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/03 05:39:47 (permalink)
polycarbonate is much harder to mill when going at production speeds. my machine will take 3/8" passes through acrylic at 300fpm cleanly where polycarbonate I need to do 1/4" passes at 50fpm. it also dulls the bits faster. so as you know the labor and machine time is much more expensive than the plastic so if i can make 4 of them or 1 of them for the same cost, i would use acrylic:)

“I built a castle in the swamp and it sunk. I built a second castle and it sunk too. I built a third castle and it burned down and then sunk. But the fourth castle, Ahhhh! That one stood.”
—Monty Python and the Holy Grail
 
nateman_doo
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/03 06:27:14 (permalink)
Carbide.  Eats through the stuff, but I still am very conservative with my depth of cuts, speeds and feeds.  Helps to keep the mill trammed when there is an absence of sheer forces, but you already know that.  Now am I reading that correctly and your cutting Fpm?!  I still keep things in IPM.
 
I just noticed I became Omnipotent last night.  Who would of thought a fluid analysis would make me omnipotent :)
 
TOTAL side note... I just purchased some I beams to hold up the estimated 800 lbs concrete table I am making for my linear rail build.  Just one more step closer.  Also I found a machinist level at work.  Might have to borrow that :)
Gentle
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/03 07:07:15 (permalink)
Is there any concern that the glitter is getting onto the solid portions of your design underneath the polycarbonate?
 
Gentle
nateman_doo
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/03 07:18:09 (permalink)
The glitter makes it obvious how much water seeps through the parts in the block that you don't want it too.  I have a plan in place, and if you look at the original drawing you can see blue on the fins which is where I wanted to put o-ring material along the fins to ensure 100% liquid flow through the fins. 

After watching this actual experiment, its obvious that liquid does flow inbetween the top plate and the main division of the block.  Its not exactly a show-stopper since 95% of the water goes where it is supposed to go simply by there being less resistance along that path, but there is some fluid that bleeds over directly into the exit port.  I am designing an additional O ring channel to guide the water along its intended path.  Just brainstorming at the moment. 
nateman_doo
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/03 08:27:02 (permalink)
This is an example of a single section of O-ring cord to help direct the flow of liquid:

 
I am a big fan of the KISS philosophy, so its still just a brainstorm at the moment.  Nice thing about a working prototype is I can put this plan into action, test it, and see if the extra trouble is worth the effort.

Attached Image(s)

Gratuitous
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/03 17:10:53 (permalink)
nateman_doo

Carbide.  Eats through the stuff, but I still am very conservative with my depth of cuts, speeds and feeds.  Helps to keep the mill trammed when there is an absence of sheer forces, but you already know that.  Now am I reading that correctly and your cutting Fpm?!  I still keep things in IPM.

I just noticed I became Omnipotent last night.  Who would of thought a fluid analysis would make me omnipotent :)

TOTAL side note... I just purchased some I beams to hold up the estimated 800 lbs concrete table I am making for my linear rail build.  Just one more step closer.  Also I found a machinist level at work.  Might have to borrow that :)

lol yah you got me there. i meant IPM. (brain fart) I wish my machine would go 3600ipm:) some do btw. but still, its a huge diferance when i can do 1 pass at 300ipm on acrylic compared to 2 passes at 50ipm on polycarb:)

“I built a castle in the swamp and it sunk. I built a second castle and it sunk too. I built a third castle and it burned down and then sunk. But the fourth castle, Ahhhh! That one stood.”
—Monty Python and the Holy Grail
 
airdeano
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/03 21:57:42 (permalink)
nateman_doo The glitter makes it obvious how much water seeps through the parts in the block that you don't want it too. 

 
nateman,
are you using sided material? we used to use two sided material and the finish was great, until the market fell out in 01. then the ally we were getting was so un-flat, we had to to either 4-sided material shizzal expensive) or plus stock to mill to a flat surface. your CAD details look familiar, GIBBS?
anyway, those are somecool details, im looking to DIY me a vert mill 24"x24"x8" for small at-home projects (and i gotsz loads of them).
+1 for the project
 
airdeano

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nateman_doo
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/04 07:10:59 (permalink)
Thanks!  nope on the Gibbs, I use ProE Wildfire for the CAD.  The CAM is pretty recent, its EnRoute4. It is a pretty limited program,  but it gets most of the legwork done as far as tool paths.  I am becoming more and more familiar with it after Gratuitous spent about 4 hours talking me through the program.  It has lots of useless tool retracts after it does an outer profile (which added over an HOUR to the overall machining of this block), so knowing the G-code helps so I just manually manipulate the tool paths. 
 
Only problem is the human factor.  If I want a 0.05 depth of cut (usually I am 0.02 on my tiny X2 mill), if I fudge the code and put Z -0.5 instead of 0.05... I am going to know I screwed up very quickly as I destroy a carbide bit and throw the machine all out of tram.
 
24x24x8 is a VERY good sized work envelope for the machine your planning.  The one i am building is 18x18x18 simply because the linear rails are 24" NSK's.  If I bought longer rails then I could have made something bigger.  Then I just have to ask myself, going from 11.5 x 7.5 x 12 to 18x18x18, what do I really need such a large work envelope for?
 
I am sure one day I will wish it was something bigger, but for what I do here now with making waterblocks (and whatever odd jobs) the Y axis was always the limiting factor.  I will be able to drop a 12x12 sheet of copper on it, and mill out both top and bottom of a waterblock (at least thats the idea).  And more importantly, run a 3" fly cutter across an entire surface of a 12x12 sheet of stock.
 
The raw material I have is usually ok, but there is always a huge gash somewhere from the goons in the warehouse manhandling the material, or bad packaging.  I try to compensate by positioning the gash into a water channel or someplace that won't effect the outcome.
 
What type of spindle box/prefab head do you plan on using?  Or you going all out and making one from scratch?  Do you already have access to a CNC, or a manual bridgeport type?
airdeano
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/04 07:27:21 (permalink)
i was going to start completely scratch, but i might have a lead on a used unit with a bosch 25k spindle and THK actuators with 425 servos.
table is mainly for my streetrod project and now PC mods. so the size is kinda the factor to fab case front facias, door trim panels, and dash plates. plus do some mold work on the side.
 
airdeano

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nateman_doo
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/04 10:05:40 (permalink)
THK and NSK seem to be some of the best (and affordable) linear rails I could find.  I just went with NSK because they were available.  If you have the time to build a new head then go for it.  I am not at that level yet, but hopefully one day I can be.  I bought a Tormach V770 head for this new build.  If only I had the time to work on that build, I still have another CNC that I have to make. 
airdeano
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/04 12:02:46 (permalink)
LOL, know what cha mean.. keep up the good work. looks fantastic.
 
airdeano

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nateman_doo
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/04 17:26:13 (permalink)
Thanks.  I now have 70 LBS OF COPPER (31.6KG for you metric types) that will soon become FOUR waterblocks!
 
I am not even close to exaggerating, 70 lbs of copper.
sputnik7913
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/04 20:39:06 (permalink)
nateman_doo

Thanks.  I now have 70 LBS OF COPPER (31.6KG for you metric types) that will soon become FOUR waterblocks!

I am not even close to exaggerating, 70 lbs of copper.

How close you think you are to start temp benches?


nateman_doo
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/05 05:48:01 (permalink)
I have a slab of copper already on the machine, but I have a busy weekend.
nateman_doo
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/06 15:00:13 (permalink)
Pics tomorrow :)
nateman_doo
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/07 10:24:15 (permalink)
Sorry for the delay, a bit under the weather today.
nateman_doo
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/08 08:13:20 (permalink)
Some first looks at the final copper block:






 
And a little idea of what some polish can do:

 
 
The block isn't finished, but its still pretty sweet to look at.  I personally can't believe how well it came out so far.
sporkimus
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/08 08:45:31 (permalink)
Any idea of what the final weight will be for the waterblock?  From the pics you provided, it looks like it'll be fairly heavy.


nateman_doo
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/08 11:26:02 (permalink)
it absolutely is heavy.  It dwarfs the SR2 block. 
sporkimus
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Re:100% Copper GTX 580 Classified Waterblock 2012/05/08 12:03:23 (permalink)
Will this cooler require some extra support to relieve the strain on the video card, such as a back plate?
 
Seeing images like this really makes me wish that I would've stuck with being a machinist to indulge in projects like these.  Although if I did, then I would've never got into computers. 


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