Skived Heat Sink:The processing technological process of skiving
1. The Processing Technological Process of Skiving
Referring to the schematic diagram above, the processing technological process of skived fin heat sinks is as follows:
1> Raw Material Preparation:
Generally, according to the requirements of the heat sink, profiles are cut, which can save raw materials to the greatest extent.
2> Blanking Treatment:
According to the product size, one product can be made in one mold or multiple products in one mold. It can be operated continuously or as a single piece.
3> Primary CNC Machining:
For example, milling off the unnecessary parts, milling the sealing ring groove, etc.
4> CNC Skiving Operation:
Skiving on a numerical control skiving machine.
5> Gear Hobbing (Flattening) Processing:
Generally completed on a gear hobbing machine.
6> Secondary CNC Machining:
According to the requirements of the product drawing, milling off the fins at the edge, or drilling holes in the middle, creating clearance spaces, facing, machining threaded holes, and making the fixture position, etc.
7> Surface Treatment Process
2. The Remarkable Advantages of Heat Dissipation Fins Produced by the Skiving Process
1> Higher Heat Dissipation Fin Density (Thinner Fin Thickness and Smaller Fin Spacing)
Skived heat dissipation fins have a higher fin density, increasing the heat exchange area within a limited volume. Profile heat sinks are limited by molds and extrusion processes, and the fin thickness and spacing cannot be too small. However, the skiving process is almost unrestricted. Even with sufficient machine accuracy, a fin thickness and spacing of 0.05 can be achieved.
2> Outstanding Heat Dissipation Fin Height
The fin height of skived heat dissipation fins can reach 120mm. Even theoretically, it can be higher, fully meeting the production requirements of heat sinks in most application scenarios.
3> Precise and Lightweight Fin Characteristics
As described in point 1, thinner fins and smaller spacing can make the heat sink lighter.
4> Integrated Structure and High Efficiency
The base plate and fins are integrated, with no additional thermal resistance increase, and the structure is more reliable. Skived heat dissipation fins are skived from the original profile. Therefore, the heat dissipation efficiency is not damaged, achieving 100% of the heat dissipation efficiency of the original profile, and there is no risk of loosening or falling off, improving the reliability of machine operation. For example, in welded fins, the phenomenon of false soldering that increases thermal resistance is likely to occur.
5> High Compatibility
Skived heat dissipation fins have high compatibility. Skived fin heat sinks are integrally formed, and there is great potential for post-processing. They can also cooperate with processes such as embedding copper pipes to improve heat dissipation performance. Whether it is soft soldering or hard soldering, they can adapt to the corresponding temperature rise during the manufacturing process.
6> Suitable for Mass Production
With the continuous improvement of the performance and efficiency of skiving machines and the continuous improvement of skiving materials, it is already suitable for mass production.
7> Wide Material Adaptability
Common heat-conducting materials such as copper, aluminum, and series alloys can all be processed by skiving. Moreover, there are currently cases of mass production of skived copper-aluminum composite materials.
8> Diverse Structural Types
In addition to common single-sided skiving, the skiving process can also produce double-sided skived fins, four-sided skived fins for pipes, annular skived fins, and irregularly shaped fins. The current technology can meet the structural design requirements of most heat dissipation fins.
9> Significant Cost Advantages
Reducing mold investment and saving development and mass production investment costs. Since no additional forming molds are required during the skiving process, for products with different size and structural requirements, only the materials, skiving cutters need to be replaced, and a new skiving program needs to be set. This can greatly shorten the sample-making time and sample-making costs, and the mass production cost is also correspondingly reduced.
Skived heat dissipation fins have a higher fin density, increasing the heat exchange area within a limited volume. Profile heat sinks are limited by molds and extrusion processes, and the fin thickness and spacing cannot be too small. However, the skiving process is almost unrestricted. Even with sufficient machine accuracy, a fin thickness and spacing of 0.05 can be achieved.
2> Outstanding Heat Dissipation Fin Height
The fin height of skived heat dissipation fins can reach 120mm. Even theoretically, it can be higher, fully meeting the production requirements of heat sinks in most application scenarios.
3> Precise and Lightweight Fin Characteristics
As described in point 1, thinner fins and smaller spacing can make the heat sink lighter.
4> Integrated Structure and High Efficiency
The base plate and fins are integrated, with no additional thermal resistance increase, and the structure is more reliable. Skived heat dissipation fins are skived from the original profile. Therefore, the heat dissipation efficiency is not damaged, achieving 100% of the heat dissipation efficiency of the original profile, and there is no risk of loosening or falling off, improving the reliability of machine operation. For example, in welded fins, the phenomenon of false soldering that increases thermal resistance is likely to occur.
5> High Compatibility
Skived heat dissipation fins have high compatibility. Skived fin heat sinks are integrally formed, and there is great potential for post-processing. They can also cooperate with processes such as embedding copper pipes to improve heat dissipation performance. Whether it is soft soldering or hard soldering, they can adapt to the corresponding temperature rise during the manufacturing process.
6> Suitable for Mass Production
With the continuous improvement of the performance and efficiency of skiving machines and the continuous improvement of skiving materials, it is already suitable for mass production.
7> Wide Material Adaptability
Common heat-conducting materials such as copper, aluminum, and series alloys can all be processed by skiving. Moreover, there are currently cases of mass production of skived copper-aluminum composite materials.
8> Diverse Structural Types
In addition to common single-sided skiving, the skiving process can also produce double-sided skived fins, four-sided skived fins for pipes, annular skived fins, and irregularly shaped fins. The current technology can meet the structural design requirements of most heat dissipation fins.
9> Significant Cost Advantages
Reducing mold investment and saving development and mass production investment costs. Since no additional forming molds are required during the skiving process, for products with different size and structural requirements, only the materials, skiving cutters need to be replaced, and a new skiving program needs to be set. This can greatly shorten the sample-making time and sample-making costs, and the mass production cost is also correspondingly reduced.
3. Application Fields of the Skiving Process and Skived Fin Heat Sinks
1> General Heat Sink Substitution: Various Types of Skived Heat Dissipation Fins
In many cases, they can replace profile heat sinks, pinned heat sinks, folded FIN heat sinks, die-casting heat sinks, and forged heat sinks.
2> Precision Heat Dissipation Field: Water Cooling Heads – Microchannel Heat Exchangers
Currently, water cooling heat sinks are very popular in products such as computer CPUs, servers, and graphics cards. The design of the water channel in the water cooling head is the key to the heat absorption efficiency during system operation. In the past, complex machining, or processes such as diffusion welding and brazing were required to manufacture the water channels, increase the heat absorption area, and improve efficiency.
The application of the skiving process can produce water cooling channels with ultra-thin fin thickness, ultra-small fin spacing, and various heights to meet the heat exchange requirements.
3> Oversized Heat Dissipation Requirements: Oversized Heat Sink Field
Currently, in the thermal management of computer rooms and energy storage systems, there is almost a demand for oversized heat sinks. The emergence of the skiving process just meets the processing requirements of such large-sized heat sinks.
In many cases, they can replace profile heat sinks, pinned heat sinks, folded FIN heat sinks, die-casting heat sinks, and forged heat sinks.
2> Precision Heat Dissipation Field: Water Cooling Heads – Microchannel Heat Exchangers
Currently, water cooling heat sinks are very popular in products such as computer CPUs, servers, and graphics cards. The design of the water channel in the water cooling head is the key to the heat absorption efficiency during system operation. In the past, complex machining, or processes such as diffusion welding and brazing were required to manufacture the water channels, increase the heat absorption area, and improve efficiency.
The application of the skiving process can produce water cooling channels with ultra-thin fin thickness, ultra-small fin spacing, and various heights to meet the heat exchange requirements.
3> Oversized Heat Dissipation Requirements: Oversized Heat Sink Field
Currently, in the thermal management of computer rooms and energy storage systems, there is almost a demand for oversized heat sinks. The emergence of the skiving process just meets the processing requirements of such large-sized heat sinks.
4. Common Material Types of Skived Heat Dissipation Fins
1> Copper Skived Heat Dissipation Fins: Copper skived fins have good thermal conductivity. Coupled with the skiving technology, the maximum heat dissipation area per unit volume can be achieved, greatly improving the overall heat dissipation performance. Therefore, copper skived heat dissipation fins are used in high-end chips, CPU heat dissipation, servers, and other fields.
2> Aluminum Skived Heat Dissipation Fins: Generally made of pure aluminum, they have a higher thermal conductivity than aluminum alloys. With the skiving process of aluminum heat sinks, the heat dissipation performance is more stable than that of aluminum extruded heat sinks. Aluminum skived heat dissipation fins are widely used in the photovoltaic industry, electric vehicles, inverters, LED lights, communication products, etc.
3> Copper-Aluminum Composite Material Skived Heat Dissipation Fins: They combine the advantages of copper skived heat dissipation fins and aluminum skived heat dissipation fins. Generally, copper is used as the basic heat-conducting material, and skiving is carried out on aluminum materials. For the process of copper-aluminum composite materials, continuous casting and semi-molten state pressing forming technology is generally adopted.
2> Aluminum Skived Heat Dissipation Fins: Generally made of pure aluminum, they have a higher thermal conductivity than aluminum alloys. With the skiving process of aluminum heat sinks, the heat dissipation performance is more stable than that of aluminum extruded heat sinks. Aluminum skived heat dissipation fins are widely used in the photovoltaic industry, electric vehicles, inverters, LED lights, communication products, etc.
3> Copper-Aluminum Composite Material Skived Heat Dissipation Fins: They combine the advantages of copper skived heat dissipation fins and aluminum skived heat dissipation fins. Generally, copper is used as the basic heat-conducting material, and skiving is carried out on aluminum materials. For the process of copper-aluminum composite materials, continuous casting and semi-molten state pressing forming technology is generally adopted.
