13.

0 : BALANCING OF MACHINES
13.1 UNBALANCE

Unbalance is the unequal distribution of weight of a rotor about its rotating axis. When
a rotor is unbalanced, it imparts vibratory force or motion to its bearings due to
centrifugal forces of the rotor. Unbalance causes vibrations on machine. The
consequences are:

 Reduced bearing life

 Inconsistent product quality
 More noise
 Slight increase in energy consumption
 Increased maintenance costs
 Fatigue failures of support structures
 Increased structural degradation.
 Operator fatigue

A properly balanced machine has less vibration. Thus, the machine must be balanced.
13.0 : BALANCING OF MACHINES
13.2 CAUSES OF UNBALANCE
Machine manufacturer must minimize the cost of manufacturing. Perfect
manufacturing results in escalated cost and many times it is not possible to do so.
Machine manufacturer usually resorts to „less than perfect manufacturing‟ of machine
components. The followings must have been compromised during manufacturing of
machine which creates unbalance on the machine :
(1) Porosity in the element/components, especially in castings.
(2) Eccentricity – the shaft journal is not concentric with the rotor.
(3) Shifting of mass center of rotor on tightening support elements.
(4) Presence of keys and keyways in rotor shaft creates a built-in unbalance.
(5) Loose parts like dirt, water, or welding slag moving around in a hollow place
(typical examples are: tin roller of a ring spinning machine and drum type
beaters).
(6) Asymmetry of a rotating part (motor windings).
(7) Cracks developed in rotor or shaft.
(8) Deformation of shaft (shaft bow) due to the relaxation of residual stresses
Further, a machine properly balanced after installation can go out of balance during its
service life due to:
(1) Changes in the mass distribution of some elements during maintenance activities
such as cleaning, drilling, grinding, changing fasteners may results in change or
mix of bolts, nuts and screws etc.
(2) Bending of shaft due to thermally induced distortion or gravity.

1
 (3) Corrosion and erosion of machine elements
(4) Deposit buildup on various elements of machine
(5) Changes in geometric axis of rotation due to wear at the journal or bearing.

13.3 PRODUCTION AND FIELD BALANCING

There are several ways of correcting excessive vibrations in machines. Machine balancing is
one of the approaches to reduce machine vibrations. In sophisticated balancing methods,
vibrations on the machine are measured and weights are added or removed to adjust the mass
distribution around the rotor, thereby reducing vibration.
Production/shop balancing is done at the machine manufacturer‟s factory after assembling
various machine parts. Unbalance of machine elements or machine might occur due
inaccurate manufacturing of components resulting from faulty design, selection of
inappropriate materials and variation in form and fit of components and the whole assembly.
Even if the above factors are taken care, while building-up a machine, an imbalance is
expected. For example, crankshafts due to their non-symmetrical shape and motor windings
due to the difficulty in winding the coils symmetrically introduce mass unbalance. To
assemble various elements of a machine without excessive force, there must be some
clearance between them, and this clearance varies within a tolerance range. The centre of
gravity of each rotating assembly varies with shape and size of mating parts and thus, the
balance condition of machine that is to be built.
But the manufacturing practice followed in industry is to manufacture machine elements as
quickly as possible and economically, assemble the moving parts, and then apply a correction
for smooth operation in the later stages of manufacture. This is the main reason for production
balancing.
A machine that is properly balanced during manufacturing can also develop an unbalance
while the machine is in use as discussed in section 13.2. For these reasons, in situ balancing is
performed on installed machines. This is called „field balancing‟.

13.0 : BALANCING OF MACHINES

13.4 MEASURES OF UNBALANCE
Unbalance can be visualized in terms of two quantities. Imaginary heavy spot on the rotor;
and vibratory forces caused due to centrifugal forces of heavy spot. These are discussed
briefly.

2
Imaginary heavy spot
Fig. 13.4.1 shows a rotor having two voids present at radii r1 and r2. Let, the deficiency of
mass at each voids are represented as -m1 and -m2. These correspond to presence of
additional masses opposite to the voids on rotor, m1 and m2. Two vectors could be drawn to
represent the voids. Each vector originates at the center of the rotor and points away from the
void that its represents. A heavy spot present at a larger radius would create more unbalance
than the one at smaller radius for a given mass of heavy spot. The magnitude of each vector
(length) corresponds to the product of additional mass on that side and the radius of cg of
additional mass (m1r1 and m2r2). The resultant vector defines the imaginary heavy spot. The
magnitude of imaginary heavy spot corresponds to the length of resulting vector. Note that the
unit of heavy spot is g-cm.

Figure 13.4.1 Rotor with two voids and the vector sum representing an imaginary heavy
spot
This process of defining a single heavy spot can be extended to any number of voids or
variations in mass density of a rotor. In general, unbalance is distributed throughout a rotor,
but, theoretically, all of the unequal weight distribution in a thin, rigid body can be combined
into a single imaginary heavy spot. This heavy spot pulls the rotor around with it, causing
bending on the shaft, and also exert cyclic forces or vibrations on the bearings. These
vibrations are measured for balancing. The first step in balancing is to find out amount of
heavy spot and its location. Then an equal counterbalancing weight is placed 180 0 opposite the
heavy spot. Alternatively, a weight is removed at the location of the heavy spot. After
properly balancing, the rotor runs smoothly without vibration.
Centrifugal force of heavy spot

3
Centrifugal force is the operative force that causes vibration due to unbalance. Unbalance
exists in a rotor whether it is rotating or stationary. The centrifugal force due to a heavy spot
becomes active only when rotor starts rotating. The centrifugal force due to heavy spot is
Fc = mrω2 ...............................................................................(13.1)
Where m = mass of the heavy spot
r = radius at which the heavy spot is located from the axis of
the rotor
ω = Angular velocity of the rotor.
When the speed is doubled, the centrifugal force quadruples.
Relationship between unbalance and vibrations on bearings
The centrifugal force from an unbalanced rotor while spinning transmits vibration on the
stationary supports (bearings). The vibration transmitted to the bearing is oscillatory. This
vibration is dependent on speed, the mass of the rotor and the stiffness of bearing supports.
Vibration transfer both force and motion on the stationary supports. The unbalance is
measured by measuring the vibrations on the stationary supports. Vibration amplitude and
phase angle are the two physical quantities associated with vibration. Accelerometers, velocity
pickups and proximity probes and other sensors are used to measure the former; while strobe
and trigger sensor methods are used to measure the phase angle. The unbalance „U‟ can be
calculated directly from the acceleration measurements of vibration. When the rotor is rigid
and supported in rigid bearings, the unbalance at each plane can be determined from the
following formula
U = Ma/ω2 ............................................................................(13.2)
Where M = Total mass in motion
a = Acceleration
ω = Angular velocity of the rotor.
13.0 : BALANCING OF MACHINES
13.5 STATIC BALANCING
The static balancing is the earliest method of mass balancing. This type of balancing is shown
in Fig. 13.5.1.
Click on Image to run the animation
Animation 13.5.1 Statically unbalanced rotor favouring the heavy spot to
the bottom

4
 Figure 13.5.1 Static Balancing of rotor placed on rigid rollers
To balance a rotor, the rotor mounted with its shaft is allowed to roll on two hard and smooth
rollers or knife-edges. The rotor rolls such that heavy spot roll to the bottom due to gravity. A
weight is then added to the top (opposite to the heavy spot) or, some amount of material is
removed at the heavy spot either by drilling or grinding. The amount of unbalance of mass is
unknown, but location of unbalance is known. By trial and error, material is added or removed
until no spot on the rotor favors the bottom. The balanced rotor could be rolled into any
position and released, it would remain stationary there.
Static balancing is still widely practiced today. It is very effective for thin disks and slow
speed rotors. Static balancing of rotor can be performed either when the rotor is removed from
the machine or in its place. In the first approach, the rotor along with its shaft is rolled over
horizontal, smooth, and hard supporting rollers or tandem rollers as described above. The
gravity moves the heavy spot to the bottom. In the second approach, the rotor is disconnected
from belts or gears and rolled. If any heavy spot is there, it rolls to the bottom.
13.0 : BALANCING OF MACHINES
13.6 STATIC UNBALANCE
Static unbalance is the result of displacement of principal mass axis of rotor with respect to
the shaft axis. The principal axis passes through the center of gravity (cg.). Due to clearance
between the journal and bearings, the shaft axis is not the same as rotational axis. As a result,
some machine parts mounted on poor quality bearings can‟t be balanced below a certain
level. Fig.13.6.1 shows the presence of static unbalance on a disk (top), and drum(bottom).
In static unbalance, the heavy spot and the center of gravity of the rotor are in the same plane

5
 Figure 13.6.1 Static unbalance on rotor: Top- disk/pulley; Bottom- drum/cylinder/
beater/tin roller
A driven pulley mounted on a beater shaft has a serious static unbalance due to defect in
casting (Fig.13.6.2). By removing materials from the pulley, the pulley is statically balanced.

Fig. 13.6.2 Statically balanced V-pulley

In a pure static unbalance condition, the vibration amplitude and phase measurements will be
identical at both bearings. This can be corrected with a single mass placed 180 0 opposite to
the heavy spot. Using knife-edge method, pure static unbalance can be detected and
corrected if the unbalance is moderate to large. However, the knife edge method of static
balancing is ineffective for heavy rotors, high-speed rotors, or where finer balance grades are
required. This is because a small residual unbalance does not create a large enough turning

6
 moment to overcome friction. This method is also not suitable for detecting couple
unbalance present in multi-axial rotors. But this method of balancing is still widely used, as
this method is very effective under certain situations. In addition, it does not require any
instrument. The location of heavy spot is evident from the part itself.
Pure static unbalance is rarely found. But, every unbalance condition has some component of
static unbalance. Static unbalance is most common form of unbalance, and if is compounded
with couple unbalance in long rotors leads to dynamic unbalance.
13.0 : BALANCING OF MACHINES
13.7 QUASI-STATIC UNBALANCE
A quasi-static unbalance condition is shown in Fig.13.7.1. Quasi-static unbalance exists
when the principal axis intersects the shaft axis at a point other than the cg of the rotor.
(i.e., the principal axis is not parallel to the shaft axis).

Figure 13.7.1 Quasi-Static unbalance

Quasi-static unbalance is very common on motor pulley combinations where the motor is
balanced, but the pulley is unbalanced. It can be corrected with a single correction weight
on the plane of pulley (Single-plane balancing). Quasi-static unbalance could be considered
as an impure static unbalance. Even though it is a single-plane unbalance, it causes a
dynamic effect with both static and a couple components.

13.0 : BALANCING OF MACHINES

13.8 COUPLE UNBALANCE
Pure couple unbalance is shown in Fig.13.8.1. Pure couple unbalance rarely occurs, but
leads to dynamic unbalance. In couple unbalance, two equal heavy spots exist at 180 0 apart
on opposite ends of the rotor. The two heavy spots do not actually have to be on ends of
the rotor. They can be anywhere along axial direction of the rotor, but the greater their
separation, the more unbalance effect they produce.

7
 Figure 13.8.1 Pure Couple Unbalance
Rotor having pure couple unbalance (as shown in Fig. 13.8.1 ) will not turn on knife-edge
supports, as they are statically balanced. However, when the rotor rotates, the centrifugal
force from the two heavy spots causes the rotor to oscillate in a conical manner. The
vibration measured at the bearings will be equal in magnitude but 180 ° out of phase for
the bearing supports of equal mass and stiffness. This implies that when one bearing is
moving up, the other is simultaneously moving down. When a bearing on the left side of
rotor moves forward, the one on the right side moves backward. Couple unbalance can
only be detected, while the rotor is rotating.
13.0 : BALANCING OF MACHINES
13.9 COUPLE UNBALANCE IN CARD CYLINDER
A single mass, can never correct couple unbalance presents on a rotor. A minimum of
two masses is required in two correction planes. On rigid rotors, the locations of the
correction weights do not have to be in the same plane and radial position as the heavy
spots. But they must create couple effects identical to that of unbalance. This is
depicted in Fig. 13.9.1 for a card cylinder.

8
 Figure 13.9.1 Correction weights and heavy spots in different planes for a rigid
rotor
Two heavy spots, each 60 g located at radius 25 cm are separated by one m along the
axis of cylinder. Each would have an unbalance of 1500 g-cm (60 x 25). The couple
effect due to this is (1500 g-cm x 100 cm) = 150 kg-cm2. If the correction weights were
to be located on the surface of cylinder 50-cm apart, then they require to have a
magnitude of 150/50=3kg-cm (i.e., couple divided by the distance between the
correction weights along the axis).
The correction weights can be placed anywhere on the cylinder, as long as they create
the same couple effect of the heavy spots and placement of them in such places would
not hinder the function of the cylinder. Placing correction weights on the base of the
carding cylinder can never be considered as they hinder the carding process. They could
be placed at smaller radii. For example two correction weights, each of 150 g at 20-cm
radius or 200 g at 15-cm radius, separated by 50-cm would balance the cylinder.
It is also possible to place one correction weight on the rotor between the bearings and
other could be outside the bearings on a separate disk mounted on the same shaft, like a
pulley. Both correction weights could be outside the bearings (on pulleys mounted on
the rotor shaft) as long as they produce the same couple effect to balance the turning
tendency of heavy spots.

13.0 : BALANCING OF MACHINES

13.10 DYNAMIC UNBALANCE
Any rotating body may be considered as composed of large number of thin disks
mounted on the shaft with their centre of gravity (cg) not perfectly coincident with the
rotational axis. Fig. 13.10.1illustrates this as condition of dynamic unbalance. This is
something like that disks are drilled with holes not at their centers but each is offset to a
different extent from the center and all are mounted on shaft. Such a rotor has a
combination of static and couple unbalance present in varying degrees. This is called

9
 dynamic unbalance, where the principal mass axis and the rotating shaft axis do not
coincide.

Figure 13.10.1 Dynamic unbalance by improperly mounted disks on the shaft

The axial distribution of disks will cause bending forces in the shaft, in addition to a
static unbalance on each disk. If the rotor is rigid enough, it will not bend, however, the
cumulative effect of couple unbalance will cause a turning moment trying to topple the
rotor end over end. This turning force causes vibration at the bearings. To properly
detect the couple component of unbalance, the rotor must be rotating. The vibration
measured on the left and right side bearings are generally unequal in amplitude, and the
phase difference is neither 0° nor 180° exactly, but somewhere in-between them.
Dynamic unbalance can be corrected on rigid rotors by two weights in two separate
planes. The two weights are not exactly 180° apart because they must also compensate
for static unbalance. After performing two-plane balancing, the amount of static and
couple unbalances that were originally present in the rotor could be determined by the
angular separation of two correction weights. If they end up on the same side, mostly
static unbalance was present. If the two-correction weights are nearly 180 ° opposite,
mostly the couple unbalance was originally present. Usually, the two weights are
unequal in weight and their angular separation lies between 00 and 1800 to compensate
for both the static and couple components.

13.0 : BALANCING OF MACHINES

13.11 DYNAMIC UNBALANCE IN AN OPENING ROLLER

An opening roller used in one of the machines of a blow room had a dynamic unbalance.
Placing two correction weights (unequal) on the periphery of the roller with angular separation
about 500 could balance the roller.
Video 11.1 A dynamically balanced opener with two correction weights
In most cases, the static component of unbalance is more important than the couple unbalance
because a static unbalance mass will usually cause a greater disturbance in vibration than two
equal unbalances in opposite directions.
13.0 : BALANCING OF MACHINES
13.12 DYNAMIC UNBALANCE IN A GROOVED WINDING DRUM

The grooved winding drums used in yarn clearing operations have dynamic unbalance due to

10
variation of mass distribution in the axial and radial planes exhibiting different amount of static
and couple unbalance ( Fig.13.12.1). The rotor must be dynamically balanced by doing
corrections only at the two extreme ends of drum, since adding correction weights or removal of
material is not possible at other places as the yarn would be traversing. Materials are removed
by drilling at few spots both at the left and right edges of drum in order to dynamically balance
the grooved drum.

Fig. 13.12.1 A dynamically balanced grooved winding drum

13.0 : BALANCING OF MACHINES
13.13 PLANE TRANSPOSITION

Plane transposition is a process of moving the two correction weights on rigid rotors along the
axis. This method is useful when correction weights could not be placed on certain locations as
observed in the case of grooved drums. Plane transposition could be carried on microprocessors
controlled balancing machines. In the first step, two correction weights are calculated and the
planes on which they have to be placed to balance the rotor are determined. The next step is to
select two separate planes (convenient to place for the correction weights that do not affect the
regular operation of machine) along the rotor axis. Third step involves calculation of the two
new correction weights required for the newly selected planes.
13.0 : BALANCING OF MACHINES
13.14 BALANCING OF A CYLINDER
For example, it is possible to correct an unbalance condition in cylinder of carding machine by
placing correction weights on the exterior pulleys, after assembling the machine. This will be
easier. Consider a cylinder of width 0.9 m, supported by four supporting elements equally
spaced along on the shaft. Due to inaccuracy of the casting of one of the support, it shows 10-g
unbalance in its plane on the base of the cylinder as shown in Fig. 13.14.1. Ideally a correction
weight of 10-g should be placed on the same plane 180 ° opposite to the heavy spot on that
support element itself. But this cannot be done, as it is not accessible without dismantling the
cylinder base. One can place the correction weights on the pulleys, i.e. pulley 1 (left side) and 2
(right side) and can balance the cylinder. Let us assume that both radii of the cylinder and
pulleys are 30 cm. Other dimensions are given in the figure. One 10-g weight (A) is placed on
the cylinder to correct the static balance of the cylinder.

11
 Figure 13.14.1 Plane transposition in balancing a cylinder
Obviously, this is not possible, and this correction weight must be moved to one of the pulleys.
Two 10-g weights can be placed on the pulley 2,1800 opposite each other. (B, placed at the
bottom and C, on the top of the pulley). This does not affect the static balance condition on the
pulley. A and B form a couple of 13500 gcm2
= [(10 * 30 * 22.5) + (10 * 30 * 22.5)]
Note : Couple = Mass x radius x axial separation about central plane. This couple can be
replaced by placing weights „y‟, one, on top of the pulley 1 and the other on the bottom of the
pulley 2. Therefore,
13500 = [(y * 30)(15 + 30 +30 +22.5) + (y * 30 * 22.5)] = 3600 yg - cm2
y = 3.75 g
Now weights on the pulley 2 are 10-g on top (original static correction weight) and 3.75- g on
bottom. This is equivalent to a weight of 6.25g placed on top of the pulley 2 (i.e. 10 – 3.75).
Finally, a balance weight of 3.75g on top of pulley 1 and 6.25g on the top of pulley 2 would
balance the cylinder statically (10 = 3.75 + 6.25).
The cylinder is also dynamically balanced, since both the static and couple unbalances are
corrected. Then the moment about any normal plane of rotor must be zero. This can be verified
with respect to the plane XX. Taking moment of inertia forces about the plane XX :
- (3.75 * 30 * 15) - (10 * 30 * 60) + (6.25 * 30 * 105)
= - 1687.5 - 18000 + 19687.5 = 0
13.0 : BALANCING OF MACHINES
13.15 TRIAL WEIGHTS

A trial weight is temporary weight placed on the rotor for the purpose of calibrating the
vibration measuring instruments. This must not be confused with correction weight. Trial
weights are placed on the rotor during balancing process, not in a trial-and-error fashion, but to
add to the exiting unbalance and modify the exiting forces. Rotor is spun at operating speed or
balancing speed (on a balancing stand) and vibrations are measured. With trial weights placed
on the rotor, again, vibrations are measured while the rotor is spinning at previous speed(s).
From these measurements, calibration of vibration measuring instrument is carried out. Further,
12
this can be used to calculate the correction weights. The trial weights should be removed from
the rotor, once the final correction weights are put in place.
13.0 : BALANCING OF MACHINES
13.16 RUN OUT
Run out is the total linear displacement measured on the outside diameter of rotor when it is
turned using dial indicator. Both the run out and mass unbalance are separate and independent
quantities. A noncircular part (cam), as shown in Fig. 11.16.1 (left), can be well balanced (by
adding balance weight) to run smoothly but it would measure a very large run out. On the other
hand, a perfectly round disk (having zero run out) but having a heavy spot (due to bolt, nut and
washer) might have a serious unbalance ( Fig 11.16.1 right).

Figure 11.16.1 A balanced cam with large run out (left); Disk with zero run out but with
serious unbalance (right)
Rotors such as, lickerin, cylinder and doffer of carding machine, and drafting rollers must have
negligible run out for smooth operation. A non-circular drafting roller creates periodic fault. For
example, if it is elliptical-shaped, then the periodicity (wavelength) of drafted fibre stand would
be one-half of the circumferences of that roller. All these elements should be mass balanced
preciously in addition to having very low run out. For rotors that do not transmit power over
their circumference, such as fans and pump, only mass balancing is sufficient to ensure smooth
operation. The permissible radial run out for plastic bobbin (tube) used in ring spinning is 0.2
mm.
Axial run out on a disk, creates a couple leading to a couple unbalance condition (refer Fig.
13.16.2). The centrifugal forces Fc around the disk are not in same plane and are separated by a
distance (d). This couple unbalance is felt at the bearings and that requires two-plane balancing.
This unbalance effect becomes significant on large diameter rotors or high-speed rotors.

13
 Figure 13.16.2 Couple due to axial run out of disk
13.0 : BALANCING OF MACHINES
13.17 UNBALANCE DUE TO ECCENTRICITY IN MOUNTING THE SHAFT
If the cg of a perfectly round and perfectly balanced rotor is displaced from its rotational axis
and forced to rotate in that condition it will go out of balance ( Fig 13.17.1). This happens if
there is a clearance between the bearing inner surface and journal surface. This shifts the
journal axis away from the bearing axis by an amount e called eccentricity which is half that of
clearance. The unbalance of rotor of mass m, due to eccentricity (e) in mounting the rotor shaft
in the bearing is
U = em .............................................................................(13.3)
When e/r is very small

14
 Figure 13.17.1 Eccentricity due to displacement of the rotating axis of
shaft in sliding contact bearing
Assume that a perfectly round and balanced thin disk is mounted on shaft whose axis is
displaced from that of bearing by 0.005 mm. If the disk and shaft together have a mass of 150
kg, then the unbalance (U) is
U = em = 0.0005 x 150000 = 75 g-cm.
It is obvious that the most fundamental principle of balancing is the direct relationship between
the unbalance of a rotor and the displacement of its center of gravity.
13.0 : BALANCING OF MACHINES
13.18 UNBALANCE DUE TO NONUNIFORM MASS DISTRIBUTION
The centre of gravity of a perfectly round disk could also be shifted from the center of rotation
due to „less than perfect‟ manufacturing processes. This might be either the disk is
inhomogeneous (non-uniform mass distribution), or the hole that is drilled on the disk for the
shaft to pass through is not made exactly at the center of the dick. A perfectly round and thin
disc of radius r, having inhomogeneous mass distribution, exhibits a heavy spot on the right
side. The rotor is balanced by placing a correction weight (Wc) on the left side ( Fig. 13.18.1).

15
 Figure 13.18.1 Eccentricity due to displacement mass cg of a disk
Before balancing the rotor, the cg of rotor moved towards right by a distance e (eccentricity)
from the bearing/rotational axis. The centrifugal force due to unbalance (F U) of spinning rotor
is
FU = Weω2 / g ..............................................................................(13.4)
Where W = Weight of rotor
ω = Rotational speed of rotor
g = Acceleration due to gravity.
After balancing the rotor, the centrifugal force due to a correction weight Wc placed at a
radius rc from the center is
FWC = Wc rc ω2 / g ........................................................................(13.5)
Where FW c is the centrifugal force due to correction weight.
If the rotor is perfectly balanced by the correction weight, then
FU = FW c ..................................................................................(13.6)
Hence, M e = Mc rc ...................................................................(13.7)
Where M and Mc are the masses of rotor and correction weight respectively.
From the above equation, it is clear that the required correction weight is a function of the rotor
weight multiplied by the displacement of its cg. Static unbalance of a rotor is the result of
displacement of its cg from its rotating axis. Anything that causes a variation in the
displacement of the cg of rotor from its rotational axis will introduce unbalance effects.
Therefore for rotating parts, manufacturing tolerances and balancing tolerances are inseparable.
Rearranging the Eq. (11.3) and (11.7), and if rc = r, we get
e = (U/M) = ( Mcrc/M) = ( Mcr/M) ..................................................(13.8)
This is called the “specific unbalance per unit mass of rotor” or “eccentricity”.
13.0 : BALANCING OF MACHINES
13.19 DYNAMIC BALANCING OF SINGLE PLANE ROTOR
Fig. 13.19.1 shows a rigid single plane rotor consisting of three masses (M1, M2 and M3),
16
rotating all in the same normal plane, about the axis.

Figure 13.19.1 Dynamically-balanced single-plane rigid-rotor

A fourth mass, MC(from the correction weight to balance the rotor) is added to the system so
that the sum of the inertia forces (oscillatory) is zero and thus, the rotor is balanced. For
constant rotational velocity of the rotor, „ω ‟, the inertia force (Fc) for any given mass (M),
placed at a radius of r from the axis, is (FC) =Mrω2
For dynamic balancing of the rotor, the vector sum of the inertia forces (ΣFc ) of the system is
zero.

Where WiMiand r [Link] the weight, mass and radii of the ith element respectively.
If the system is balanced by a correction weight (Wc) placed at a radius rc, then

17
Where θi and θc are the phase angles of ith element and correction weight, counter-clockwise
measured from x-axis.
Any number of masses rotating in a common radial plane may be balanced with a single mass
(a single correction weight). If the mass and radii of centre of gravity of all elements with their
phase angles are known, then one can calculate the product of correcting mass and its radial
position and phase angle using the above two Eq. (13.13) and (13.14). The unbalance can also
be determined analytically by summing x- and y- components. This is illustrated in the
following Table 13.19.1.
Table 13.19.1 Balance of inertia forces

From this, the weight times the radius of correcting element (i.e. the resultant force R) can be
calculated as,

13.0 : BALANCING OF MACHINES

13.20 DYNAMIC BALANCING OF MULTI-PLANE ROTOR
Consider a case in which the rotating masses of a rigid rotor lie in a common axial plane
shown in Fig. 13.20.1. In this case, the inertia forces are parallel vectors.
18
 Figure 13.20.1 Dynamically-balanced multi-plane rigid-rotor
Balance of inertia forces is achieved by satisfying the equation ( 13.11). However, balance of
the moments of inertia is also required to dynamically balance this rotor. In the case of single
plane rotor (Fig.13.19.1), moment equilibrium is inherent since the inertia force vectors are
concurrent. However, inFig.13.20.1, it is oblivious that the inertia forces are not concurrent
when viewed in the axial plane. In order to balance the moments, the moment of inertia forces
about an arbitrarily chosen axis normal to the axial plane (selected at O) must be zero, i.e.

Where, ac is the moment arm of correction weight about the normal plane at O.
Tabulation method may be used to calculate the resultant unbalance, (ΣWr) and aC. This is
shown in the following Table 13.20.1.

19
 Table 13.20.1 Balance of moments

In Table 13.20.1, upward Wr values are taken as positive. The counterclockwise values
of Wra are positive. The distance aC from the moment centre O locates the line of action of
correction weight (R). To satisfy the Eq. (13.11) and (13.17), the equilibrant (ΣWr ) is equal,
opposite, and collinear with R. Then,

13.0 : BALANCING OF MACHINES

13.21 DYNAMIC AND STATIC BALANCING
Fig. 13.21.1 shows a rigid rotor with shaft laid on horizontal parallel ways.

20
 Figure 13.21.1 Dynamically unbalanced single-plane rigid-rotor
If the rotor is statically balanced, it will not roll under the action of gravity, regardless of the
angular position of the rotor. The requirement for static balance is that the center of gravity of
the system of masses be at the axis of rotation. For the center of gravity to be at the axis of
rotation, the moment of inertia of masses about the x-axis and y- axis, respectively, must be
zero.

So, this rotor does not meet the conditions for static balance (equations 13.20 & 13.21). So the
rotor is not statically balanced and hence, it is not dynamically balanced.
For dynamic balancing of rotors, Eq. (13.11) and (13.17) must be satisfied for single plane
rotor and multi-plane rotors respectively. It can be said that if the rotor is dynamically balanced
then it is also statically balanced (as demonstrated in Fig. 13.19.1& 13.20.1). The converse is
not true for all the rotors. A statically balanced rotor is not always dynamically balanced, the
exception being the single plane rotors. This is illustrated by the following example.
Consider the multi-plane rotor shown in Fig. 13.21.2.

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 Figure 13.21.2 Multi-plane rotor statically balanced but dynamically unbalanced without
correction weights and dynamically balanced after placing correction weights
The above rotor is statically balanced without the correction weight (W C), as
(27 X 10.5) – (27 X 10.5) = 275 - 275 = 0
But the rotor is not dynamically balanced (condition for Eq. 13.17 is not met), as,
(27 X 10.5 X 5.5) – (27 X 10.5 X 15) ≠ 0
By placing two correction weights (Wc), each 64.3 N at the locations (radial and axial planes
shown in the figure) the rotor is dynamically balanced, as
(27 X 10.5 X 5.5) – (27 X 10.5 X 15) + (64.3 X 7 X 14) – (64.3 x 7 X 8) = 0
Thus, static balance fails to indicate moment balance required for the dynamic case. A static
balance is a reliable test of dynamic balance only in the case of single plane rotors
(example: Fig. 13.19.1 ), where all the masses lie in a common transverse plane and dynamic
unbalance of moment is unlikely.
Practical examples of balanced multi-plane rotors can be found in chapter 6. The epicycle gear
train shown in Fig 6.10.2 has two sets of planetary gears (B and C) of different size/mass
mounted on the same arm (i.e. on sides of the sun gear F). The planes containing the gears B
and C is statically balanced by having three gears in each plane with 120 0 angular separations
(i.e., Σ(Wr) = 0). Similar is the case with plane containing the gear set B.
The wholes system (rotor) comprising of sun and two sets of planetary gears is dynamically
balanced. This is by placing the bigger gear set 'C‟ at a short distance (aC) from the mid plane
of gear F; while the smaller gear set B is place at longer distance (aB) from the mid plane of
gear F. If the weight of the gear sets are WB and W C respectively, then,
WBr aB = WC r aC
13.0 : BALANCING OF MACHINES

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 13.22 PRACTICAL ASPECTS OF BALANCING
Balancing of machines is sometimes risky. During balancing, the equipment to be balanced
is in unsafe position. Before balancing, many practical aspects have to be considered. A
machine or machine part may go out of balance after maintenance. The following actions
carried out during maintenance of a machine might affect its balance :
 Changing of bearings, pulleys and couplings.
 Rearranging the fasteners (bolts, washers, and nuts) that are not at all identical on
weight.
 Thermal distortion due to welding.
 Changing the orientation of assembly clearances. (eccentricity due to fit) .

Maintenance activity related to shaft fit

Consider a pulley with shaft mounted on rolling contact bearing. Some clearance is required
between the inner race of bearing and outer surface of shaft, so that the shaft is inserted into
the inner race of bearing without interference. With this position, the shaft is held with bolt
or screws. On spinning the rotor, it will be out of balance. The unbalance must be corrected
by placing correction weight(s). This is shown in Fig. 13.22.1(a). Note that the shaft is
moved towards right in the bearing and the rotor has excess material on it right side. Hence,
the rotor is balanced by placing correction weight at left side. If the clearance between the
shaft outer surface and bearing inner surface is 0.005 cm, then the eccentricity is 0.0025 cm
( refer the figure).

Figure 13.22.1 Eccentricity and unbalance in rolling contact bearing before and after
maintenance operation
Let us calculate the magnitude of unbalance originally present on the rotor and correction
weight added to balance the rotor as depicted in Fig 13.22.1(a). From the following data for
the rotor, these can be calculated.

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Rotor speed = 900 rpm, corresponds to angular speed, ω = 94.25 radians/s.
Radius of pulley, r = 20 cm
Thickness of pulley, t = 4 cm
The area of excess material on the right side of the pulley based on Eq. ( 7.31) is equal to :
π[(20)2 – (20 – 0.0025) 2] ÷ 4 = 0.0785 cm2. From Eq. ( 7.32) the mass of excess material
of the pulley on one side is 0.0785 x 4 x 7.8 = 2.4504 g. Since there is an absence of
material at the left side, the heavy spot on the right side of pulley from Eq. ( 7.33) is 2 x
2.4504 = 4.894 g at a radius 20 cm. The centrifugal force due to the heavy spot of wheel
fromEq. (7.34) is 4.894x 20 x (94.25)2 = 85.2 N. The correction weight of 4.894 g is placed
on the left side of pulley to balance the rotor.
After maintenance operation, when the shaft is refit into the bearing with inner race rotated
by 1800, the heavy spot and the correction weight will be on the left side of pulley as shown
inFig. 13.22.1(b). Then the excess material on the right side of pulley is: 2 x 4.894 = 9.79 g
at a radius of 20 cm. Thus, the unbalance and the amplitude of vibratory force on the
bearing is doubled; and the effect is much serious than the one before the maintenance
operation.
Removing materials and adding weights
For removing excess weights, drilling, milling, grinding and laser vaporizing are used. Care
should be taken so that the structural integrity of rotating body is not compromised while
removing the excess material. The outside diameter is the most favoured location for weight
removal, because to attain the same effect, least amount of material is removed at outer
surfaces compared to removing materials at the inner side. In addition, the stresses are
lowest on the outer circumference.
Correction weights may be in the form of clips, weld, adhesive backing, soldering, epoxy
resins, screws, washers, bolts, nuts and rivets. In the case of unbalance due to the coils of
armature of an electric motor, the unbalance should be corrected at planes other than the
armature such as pulley on the motor or cooling fan blade etc.

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