INTRODUCTION TO

BALANCING

MAIN FEATURES OF PRESENTATION

1. 2. 3.

What is Balancing Unbalance and its Units Causes of Unbalance

4.
5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Relation of Unbalance with speed

Vibration due to unbalance Why balancing is important Advantages of Balancing Types of Unbalance Methods used for Balancing Balancing Operations Balancing Machines Balancing Speed Balance Quality Grades Balance Tolerances

15.

Key Conventions for Balancing

1. WHAT IS BALANCING
It is a technique for determining the amount and location of heavy spot so that an equal amount of weight can be removed at this

location, or an equal amount of weight added

directly opposite.

2. UNBALANCE AND ITS UNITS

The unequal distribution of the weight of the rotor about its rotating centerline.

Or
According to International Standards Organization (ISO): That condition which exists in a rotor when vibratory forces or motion is imparted to its bearings as a result of centrifugal forces.

UNITS OF UNBALNACE:
Unbalance is normally measured in ounce-inch, graminch, gram-mm.

3. CAUSES OF UNBALANCE

1. Blow Holes in castings 2. Eccentricity 3. Addition of keys and key ways 4. Distortion 6. Corrosion and wear 7. Deposit build up

4. RELATION OF UNBALANCE WITH SPEED

Unbalance in a rotating shaft develops a centrifugal force that acts on the running shaft in the same way that any applied force would and will bend the shaft in the same way that it would if the shaft were at stand still.

Fc = m x r x 2 = unbalance x [ 2 x x N / 60 ]2
Or Example: Fc RPM2

The force created by a 3 ounce weight attached at a radius of 30 on 3600 RPM rotor is over 2000 lbs, by doubling the speed to 7200 RPM the unbalance force is increased to over 8000 lbs.

4. RELATION OF UNBALANCE WITH SPEED (CONT.)

5. VIBRATION DUE TO UNBALANCE

The vibration caused by unbalance occurs at a frequency equal to 1 x RPM of the unbalanced part, and the amplitude of vibration is proportional to the amount of unbalance present.

Normally, the largest amplitudes will be measured in the radial (horizontal or vertical) direction.

SPECTRUM OF UNBALANCE

6. WHY BALANCING IS IMPORTANT

Forces created by unbalance are detrimental to the life of the machine, the rotor, the bearings and the supporting structure. Example: Rating life of an SKF 6209 Ball Bearing is, L10 = a x (c / p)3 x (16667 / N) Where, L10 = Rated life of the bearing a = adjustment factor = 1.8 c = Rated bearing load (7460 lbs for this example)

P = Actual radial load (395 lbs for this example)

N = RPM of machine = 2000, say On substituting the values,

L10 = 101,000 hours or 11.5 Years

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6. WHY BALANCING IS IMPORTANT (CONT.)

If unbalance is say, 7.50 ounce-inch,

Then centrifugal force at bearing is

Fc = 1.77 [ RPM / 1000 ]2 x Unbalance

Fc = 53.1 lbs due to unbalance

If additional unbalance load of 53 lbs is added to radial load, P, the calculated life of the bearing is reduced to 69,253 hours or 7.9 years i.e. the additional 53 lbs of force due to unbalance reduces bearing life by 30%!!
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7. ADVANTAGES OF BALANCING

1. 2.

Increased machine service life Reduced down time and repair costs

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8. TYPES OF UNBALANCE

1. Static or Force Unbalance

2. Couple Unbalance
3. Combination of Static and Couple

unbalance
a. Quasi-Static Unbalance b. Dynamic Unbalance Test Run
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8. TYPES OF UNBALANCE (CONT.)

1. Static or Force Unbalance

That condition of unbalance where the central principal is displaced parallel to the rotating center line.
It can be corrected by adding or removing weight in only one correction plane.

It can be detected on placing the work piece on the knife-edge.

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8. TYPES OF UNBALANCE (CONT.)

2. Couple Unbalance That condition of unbalance where the central principal axis intersects the rotating centerline at the rotor center of gravity. It is created by a heavy spot at each end of the rotor, but on opposite side of the centerline.

It cant be detected by placing work piece on knife edges. It becomes apparent only when the part is rotated. Couple unbalance can only be corrected in two planes. 15

8. TYPES OF UNBALANCE (CONT.)

3. Combination of Static and Couple unbalance a. Quasi-Static Unbalance That condition where the central principal axis intersects the rotating centerline but not at the center of gravity. Here static unbalance is directly in line with one of the couple moments. It can only be corrected in two planes.
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8. TYPES OF UNBALANCE (CONT.) b. Dynamic Unbalance

Unbalance where the central principal axis and the rotating centerline do not coincide or touch. Here static unbalance is not in direct line with either couple moment. As a result, the central principal axis is both tilted and displaced from the rotating centerline.

It can only be corrected in two planes.

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9. METHODS USED FOR BALANCING

1. Single Plane
2. Two Plane 3. Multi Plane

No. of balance correction planes should be based on length to diameter ratio (exclusive of the supporting shaft) L / D < 0.5 [Single plane balance for operating speeds up to 1000 RPM]
(Above 1000 RPM two plane is often required)

Example
Single sheave pulleys, Grinding wheels and etc.
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9. METHODS USED FOR BALANCING (CONT.)

If,
L / D > 0.5 [Two plane balancing for operating speeds greater than 150 RPM]

Cross Effect
The effect on the unbalance indication at one end of a rotor caused by unbalance at the opposite end. Because of cross effect, the unbalance indications observed at each end of a rotor do not truly represent the unbalance in their respective correction planes. Instead, each indication will be the resultant of unbalance in the associated correction plane plus cross effect from the opposite end.

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CROSS EFFECT

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10. BALANCING OPEARATIONS

1. In place or Field Balancing 2. Shop Balancing .

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11. BALANCING MACHINES

The purpose of balancing machine is to determine magnitude by of some technique and both its the

unbalance

angular

position in each of the selected planes.

1. Gravity Balancing Machines 2. Centrifugal Machines
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11. BALANCING MACHINES (CONT.)

1. Gravity Balancing Machines Gravity balancing machines also called non rotating balancing machines are capable of only detecting or indicating static unbalance. 2. Centrifugal Machines In Centrifugal machines the rotor is supported by the machine and rotated around a horizontal and vertical axis, usually by the drive motor of the machines. This machine is capable of measuring static, couple and dynamic unbalance. Two types of centrifugal of dynamic balancing machines are in general use today. 1. Soft or Flexible Bearing Machine 2. Hard or Rigid Bearing Machines
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11. BALANCING MACHINES (CONT.)

1. Soft or Flexible Bearing Machine Soft or flexible bearing machine derives its name from the fact that it supports the rotor to be balanced on bearings that are free to move in at least one direction, usually horizontal, perpendicular to the rotor axis. The resonance of the rotor and bearing system occurs at one half or less of the lowest balancing speed. By the time balancing speed is reached, the angle of lag and vibration amplitude have stabilized and can be measured with accuracy. Balancing speed range is above the resonant speed of suppots.
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SOFT OR FLEXIBLE BEARING MACHINE

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11. BALANCING MACHINES (CONT.)

2. Hard or Rigid Bearing Machines Similar to soft bearing machines Bearing supports are significantly stiffer in the horizontal direction, results in a horizontal resonance which is much higher than the resonance in a soft bearing machine. Resonant speed frequency of the rotor bearing support system is usually more than three times greater than the maximum balancing speed. Balancing speed range is well below the resonant speed of supports. Suspension members are rigid. Massive stiff foundation required.

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COMPARISON OF SOFT AND HARD BEARING BALANCING MACHINES

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12. BALANCING SPEED

A rigid rotor i.e. a rotor whose unbalance is independent of rotation up to its operating speed may be balance at a speed just high enough to ensure that the unbalance will be below the acceptable tolerance. Balancing speed is usually lower than the rotating speed. Advantages 1. The time required to accelerate the rotor to the balance speed is shorter 2. Less hazardous and safety features are simpler 3. Drive power is reduced
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13. BALANCE QUALITY GRADES

What does Quality Grades mean: Quality grade e.g. G2.5 is simply a calculated no. that represents a value that will produce a satisfactory vibration level in a general purpose machine when operating in its own environment. The numerical value of G is equal to the vibration velocity in mm / sec of a freely suspended rotor.

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13. BALANCE QUALITY GRADES

(CONT.)

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13. BALANCE QUALITY GRADES (CONT.)

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14. BALANCE TOLERANCES

Here tolerance means, residual unblance Standards 1. ISO Standard no. 1940 (Balanced Quality of Rotating Rigid Bodies) 2. American National Standards Institute ANSI S2.19 1975 3. Acoustical Society of America as ASA STD 2 1975 These standards relates to acceptable residual unbalance as a function of maximum service speed. Larger the rotor mass, the greater the permissible unbalance,

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14. BALANCE TOLERANCES (CONT.)

ISO Formula U = G x 4763 x W / N Where, U = Permissible residual unbalance for each correction plane in g mm W = Rotor weight in Kg N = Maximum continuous operating speed G = ISO balance quality grade no. e.g. 6.3, 2.5 and etc.

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14. BALANCE TOLERANCES (CONT.)

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14. BALANCE TOLERANCES (CONT.)

Example: Rotor of DB-711 W = 281 Kg N = 900 RPM G = 2.5 From table, Total residual unbalance for rotor is g mm / Kg = 25 or g mm = 25 x 281 = 7025 For one plane g mm = 7025 / 2 = 3512.5 in this case, correction radius for balance weight on plane no. 1 = 175 mm so, Residual weight for plane no. 1 = 3512.5 / 175 = 20.1 g

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14. BALANCE TOLERANCES (CONT.)

Similarly, correction radius for balance weight on plane no. 2 = 175 mm so, Residual weight for plane no. 2 = 3512.5 / 175 = 20.1 g ISO formula U = G x 4763 x W / N Here, G = 2.5 So, U / Plane = 2.5 x 4763 x 281 / 900 = 3717.8 g mm As, correction radius for both planes is 175 mm So, Residual weight for each plane = 3717.8 / 175 = 21.2 g

% age error = 5.7

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15. KEY CONVENTIONS FOR BALANCING

Keys play a significant part in controlling the unbalance in any rotor. Example 4 x 7/8 x 7/8 key weigh = 396 g let, radius of the key from the shaft center = 51 mm then, key represents unbalance = 20196 g mm for an armature, let, W = 454 Kg N = 1800 RPM According to ISO formula, Unbalance = 3003.3 g-mm / plane (G = 2.5) Key unbalance is almost 7 times the G2.5 standard!! The ISO standard requires that a half key be used when balancing components of a keyed assembly 37

15. KEY CONVENTIONS FOR BALANCING

(CONT.)

Objectives: Make it appear that a key way has not been machined in the shaft by filling the void with a half key. ISO conventions for shaft half length keys: 1. If key has a square cross section, cut a length of key stock equal to 48% of the final key length. 2. For rectangular key cross section up to 5/16 wide, the weight of the half length key should be 45% of the final key weight. For wider rectangular keys ( > 5/16) half length keys should weigh 54% of the final key. (Reference: ISO Standard 8821:1989, Key Conventions for Balancing)

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15. KEY CONVENTIONS FOR BALANCING

(CONT.)

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SPECIAL THANKS TO: SYED MUHAMMAD ZAIDI MUHAMMAD SAEED

PRESENTED BY: ADEEL SHAKOOR

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