Proceedings of Second Shri Chhatrapati Shivaji Maharaj QIP Conference on Engineering Innovations

Organized by Shri Chhatrapati Shivaji Maharaj College of Engineering, Ahmednagar

In Association with Novateur Publications JournalNX-ISSN No: 2581-4230
February, 22nd and 23rd, 2019
Design of Dynamic Balancing Machine

Ranjit Vasant Rajale1 Abhimanu Indrabhan Tarade2

Mechanical Engineering Department, Mechanical Engineering Department,
SCSMCOE ,NEPTI SCSMCOE ,NEPTI
AHMEDNAGAR,INDIA AHMEDNAGAR,INDIA
[email protected] [email protected]

Abstract— this work is an attempt to evolve a means for dynamics more challenging as compared to the structural
statically and dynamical balancing of mechanical components. dynamics. [2]
This will no doubt evolve greater success in ensuring sound The most important and fundamental procedure to
fabrication of our local machine and ensuring that life span of unfavorable vibrations is to eliminate geometric unbalance
such machine is prolonged since vibration will be reduced to the present in the rotor. The balancing procedure for rigid rotor
barest minimum.
Every wheel and its shaft have to be in a state of balanced, two
was established relatively early. The arrival of high speed
mating shaft in rotation have to be in a state of static and dynamic rotating machines made it necessary to develop balancing
balance. This is because unbalance condition produce centrifugal technique for flexible rotors. Two representative theories were
force which increase as the speed of the machine increase, causing proposed for flexible rotors. One was modal balancing method
damage to machine parts. and the other was influence coefficient method. Vibration
To achieve the aim of static and dynamic balancing, various response measurements yield a great deal of information
design alternatives for achieving the design solution were concerning any faults within rotating machines. Cracks in shaft
synthesized and a choice of economic method which will satisfy have long been identified as factors limiting safe and reliable
the objective was made. Based on the principle guiding the operation of turbo machines. They can sometimes result in
performance of the machine, the dimension and size of the various
components were established and correctly selected and the basic
catastrophic failure of equipment and more often, in costly
static and dynamic apparatus was fabricated and after testing it process upsets, repairs and premature scrapping and
was found to satisfy the objective. replacement of equipment. It was pointed out that transverse
Keywords-dynamic ,Static,Rotors, vibrations are very common in rotor system due to residual
unbalance, which is the most inherent fault in rotor. Self-
Introduction excited vibrations are disturbances belong to a fundamentally
Power transmission in engineering is accomplished by the different class as compared to free or forced vibrations. In self
use of shafts bearings, pulleys, belts, rollers, gears, couplings, excited vibrations, the excitation force sustains the motion is
etc. Most machine members are linked or interconnected with created or controlled by motion itself, when the motions stops
one another before this power transmission can be effective. the excitation force disappears. On forced vibration sustaining
Misalignment or out of balance of shafts or any of these excitation force exists independent of motion and persists even
machine members results in excessive vibration which is when the vibratory motion is stopped. An unbalanced disc
transmitted to other members and down to the foundation bolt mounted on flexible shaft running in two bearings executes an
and therefore in fatigue stress on the members. Fatigue, ordinary transverse forced vibration. [3]
probably, is responsible for over 70% of failure of engineering
I. LITERATURE REVIEW
component in operation. Misalignment in shafts and bearing
causes excessive load. High speed bearing of aircrafts that may Miklos T. Koncz explained in the paper entitled ‘Design of
operate at over 20,000 rpm may become catastrophic if there low cost balancing machine for gas turbine of UAV’ that
be any unbalance of the members. Out of balance of machine Balancing of the rotor is one of the most important crucial key
members creates serious problems on the functionality and elements of a gas turbine construction. It is true for amateur,
durability and machine members and on the machine in semi-professional and professional field as well. In this article
general. the author presented a new method for balancing small-scale
Since rotating machinery is omnipresent right from gas turbine. During the experimental phase his main aim was
household machinery, automotives, marines to space to implement a sophisticated balancing machine for
applications and hence understanding dynamic behavior of homebuilders and semi-professionals without large investment,
rotating machinery is crucial for long life of machinery and complicated electronics and mechanics. Every balancing
safety of humans. Rotor dynamics deals with these aspects and machine consists of two parts: mechanics and electronics
hence its study is very important for design engineers and field and/or software. The design concept of the mechanical part is
engineers. As compared to structural vibrations the rotor to provide easy balancing of complete turbine. This in situ, soft
dynamics differs in several ways as rotating machineries have suspension, balancing system (balancing in own support) helps
inherent forces and moments due to dynamics of various to correct the unbalance problems coming from bearings and
machine elements or faults occur in them also gyroscopic shaft misalignments (angular and parallel). The other
effect which is predominant at higher speeds makes the natural advantage of this system was implementing the balancing
frequency speed dependent. Bearings and seals also make instrumentation virtually without electronics. Only an
natural frequency of the rotor system speed dependent, electronic switch provides the selection between left and right
moreover, it also makes system unstable. An asymmetry in signal of the sensors. All measurement functions are
rotors due to operational requirements such as keyways or slots implemented by software with digital signal processing
in rotors causes the rotor instability. The internal damping method, average workshop personal computer and low cost
hysteric and friction between two mating parts in rotors makes soundcard.
the system unstable and there are several other reasons for the Generally speaking unbalance is one but not only source of
instability due to working fluid interaction with rotor the vibration of the rotating engine. Unbalance force generates
components. Above mentioned reasons makes the rotor vibration, but the resonance can gain it at a representative
revolution speed. The resonance can be characterized by
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 Proceedings of Second Shri Chhatrapati Shivaji Maharaj QIP Conference on Engineering Innovations
Organized by Shri Chhatrapati Shivaji Maharaj College of Engineering, Ahmednagar
In Association with Novateur Publications JournalNX-ISSN No: 2581-4230
February, 22nd and 23rd, 2019
amplitude emphasis and 180° phase changing around and computational analysis result was found to be in close
resonance frequency. If resonance exists in the system the match with analytical result.
balancing decreases its effects, but only for temporary time, Static flexure is basically a parallelogram mechanism
because small mechanical changing can cause large vibrated which is designed to produce a linear translation motion on the
amplitude amplification. In this case the resonating part must application of centrifugal load F due to static unbalance. It
be enforced (stronger spring force) to eliminate the resonance. consists of set of fixed guided beam connected in parallel with
The program and mechanics proved to be useable for balancing mechanical amplifier. The mechanical amplifier amplifies the
Phoenix Mk-4. There are some disadvantages of this balancing harmonic motion of static flexure and improves the
solution, but these can be corrected by enhancing the program measurement accuracy. Dynamic flexure is designed to
and rebuilding the mechanics.[4] measure the dynamic unbalance in satellite. It consists of two
Rajeev Chaturvedi and Shree Niwas Sahu explained in their Tie rod separated by distance W and a flexure pivot. During
paper entitled ‘Design and analysis of vertical dynamic spinning the forces generates moment about the flexure pivot
balancing machine flexure for satellite balancing’ that Mass which causes the harmonic oscillation about the flexure
properties of the satellite refer to properties of a body like pivot.Fig-6 shows the schematic of the dynamic flexure. For
Mass, Centre of gravity (C.G.), moment of inertia and product small oscillation θ about the flexure pivot. Strain δy /LD in tie
of inertia. Chobotov (1991) in his book has explained the rod related to axial load P in the tie rod as P δy AE LD
significance of Mass properties of satellite. Further the test where A is are of cross section of tie rod , LD is length and E is
shows how Mass properties of satellite are used during attitude young Modulus.[5]
and orbital control. In the life cycle of development of satellite Jim Lyons explained in paper entitled ‘Dynamic Balancing-
it is essential to know and control these mass properties for Causes, Corrections and Consequences’ that when man
desired performance. Satellite mass properties viz. Mass, C.G. invented he very quickly if it wasn’t completely round and it
are the deciding parameter in selection of launch vehicle and didn’t rotate evenly its central axis, then he had a problem. The
hence affect the overall budget of the project. Satellite mass wheel would vibrate, causing damage to itself and it’s support
properties are also vital parameter for the design of its interface mechanism and in severe cases, be unusable. As the task of
on launch vehicle, thrusters specifications and there location. manufacturing mechanism and in severe cases, be unusable. As
Accurate measurements of mass properties enhance the the task of manufacturing to minimize the problem. Research
mission life of the project by effective utilization of showed that the wheel and its shaft had be in a state of balance,
propellants. i.e. the mass had to be evenly distributed about the rotating
A satellite consists of various subsystems and payloads centerline so that the resultant vibration was at a minimum.
having unsymmetrical shape that create complicacy in This had to be achieved during the manufacturing process (and
theoretical assessment of mass properties, also satellite harness, perhaps just as importantly, as wear occurred) so that
thermal elements viz. multilayer insulation, heater etc maximum service life could be achieved from the system.
contribute to mass properties. Owing to irregular shape it is not Modern man still suffers from the same problem – only now
possible to get exact theoretical assessment of mass properties the problem is amplified. As machines get bigger and go faster,
of the satellite and therefore arises the need to measure mass the effect of the unbalance is much more severe. Many causes
properties of fully configured satellite. Mass properties of are listed as contributing to an unbalance condition, including
satellite are measured in-house in ISRO satellite centre, material problems such as density, porosity, voids and
Bangalore. Measurement of static and dynamic unbalance blowholes. Fabrication problems such as misshapen castings,
present in satellite is done on in-house developed Vertical eccentric machining and poor assembly. Distortion problems
dynamic balancing machine (VDBM). Vertical dynamic such as rotational stresses, aerodynamics and temperature
balancing machine (VDBM) has key components comprising changes. Even inherent rotor design criteria that cannot be
of Hydrostatic bearing, DC drive, Flexures, Velocity pick up avoided. Many of these occur during manufacture, others
transducer and Data acquisition System. Fig-1 shows the during the operational life of the machine. Whilst some
satellite balancing on VDBM. The Spacecraft to be balanced is corrections for eccentricity can be counteracted by balancing, it
mounted on the VDBM using suitable interface fixture. When is a compromise. Dynamic balancing should not be a substitute
the spacecraft is spun about its axis, the static and dynamic for poor machining or other compromise manufacturing
unbalance present in the spacecraft causes oscillatory motion of practices. In the manufacturing process, if proper care is taken
the static and dynamic flexures which are simple harmonic in to ensure that castings are sound and machining is concentric,
nature. These harmonic motions of the static and dynamic then it follows that the two axis will coincide and the
flexures are sensed by the respective sensors and they assembled rotor will be in a state of balance.[3]
proportionately convert the mechanical input of harmonic A level of unbalance that is acceptable at a low speed is
motion into electrical voltage output. These readings are used completely unacceptable at a higher speed. This is because the
to compute the actual static and dynamic unbalance present in unbalance condition produces centrifugal force, which
the satellite with the help of calibration constants This paper increases as the speed increases. In fact, the force formula
discusses the design of flexure for measurement of static shows that the force caused by unbalance increases by the
unbalance (centre of gravity) and dynamic unbalance (Product square of the speed. If the speed is doubled, the force
of inertia) in the body. Liberalized displacement relations are quadruples; if the speed is tripled the force increases by a factor
derived to measure the force and moment through the flexure. of nine! It is the force that causes vibration of the bearings and
Analytical studies based on kinematic modeling and surrounding structure. Prolonged exposure to the vibration
computational modeling, as well as experimental study was results in damage and increased downtime of the machine.
conducted to investigate working of the flexure. Experimental Vibration can also be transmitted to adjacent machinery,
affecting their accuracy or performance. The key phrase being

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 Proceedings of Second Shri Chhatrapati Shivaji Maharaj QIP Conference on Engineering Innovations
Organized by Shri Chhatrapati Shivaji Maharaj College of Engineering, Ahmednagar
In Association with Novateur Publications JournalNX-ISSN No: 2581-4230
February, 22nd and 23rd, 2019
“rotating centerline” as opposed to “geometric centerline”. The IV. TYPES OF UNBALANCE
rotating centerline being defined as the axis about which the
rotor would rotate if not constrained by its bearings. The The location of the centre of mass and the principal
geometric centerline being the physical centerline of the insertion axis is determined by the counter balancing effect
rotor.[4] from every element of the part. However, any condition of
When the two centerlines are coincident, then the rotor will unbalance can be corrected by applying or removing weight
be in a state of balance. The geometric centerline being the at a particular radius and angle. In fact, the amount of
physical centerline of the rotor. When the two centerlines are
unbalance can be correctly stated as weight time radius r
coincident, then the rotor will be in a state of balance. Even
inherent rotor design criteria that cannot be avoided. Many of U = mr
these occur during manufacture, others during the operational
life of the machine. When unbalance has been identified and The types of unbalance are static unbalance, couple
quantified, the correction is straightforward. Weight has to be unbalance and dynamic unbalance. [1]
either added or removed from the rotating element. The
ultimate aim being to reduce the uneven mass distribution so V. STATIC UNBALANCE
that the centrifugal forces and hence the vibrations induced in
the supporting structures are at an acceptable level. This is a condition that exists when the centre of mass
Everything that rotates needs to be in a state of balance to is not on the axis of rotation static unbalance requires only are
ensure smooth running when in operation. Precision balancing correction. The amount of unbalance is the product of the
is essential to the manufacture of rotating equipment and to the weight and radius. This type of unbalance is a vector and
repair and renovation of installed machines. As machine speeds therefore must be corrected with a known weight a particular
increase, the effects of unbalance become more detrimental. angle. Force unbalance is another name for static unbalance
Modern technology allows for accurate balancing to be
performed both in the field and in the workshop. Increased
time between outages and availability for production is the
prime benefit.[6]
.

II. PROBLEM STATEMENT AND OBJECTIVES

Problem statement
Power transmission devices mainly consist of rotating
elements such as shafts, bearings, pulleys. If there is any
misalignment in shaft or any unbalance in rotating elements or
both of these causes excessive vibration which causes fatigue
stresses in machine element which leads to failure of machine
components in operation. Fig.1 Statically Unbalanced System
Objective:
The objective of this project is to design, construct and test VI. DYNAMIC UNBALANCE
a basic static and dynamic balancing apparatus as one of the This is also known as tow plane unbalance, it is the Victoria
ways to prevent premature failure of engineering components summation of force and couple unbalance. It is the most
due to fatigue loading. common condition found in virtually all rotors. The
specification of unbalance is only complete if the serial
location of the correction plane is known. Dynamic unbalance
or two – plane unbalance specifies all the unbalance which
III. WHAT IS BALANCING exists in the work – piece. These types of unbalance can only
Balancing is the processing of minimizing vibration, noise be measured on a spring.[1]
and bearing wear of rotating bodies as well as the adding or Marcellus Celly:
removal of material from non – rotating parts to change the Merrill invented his electronic dynamic allowed the
centre of gravity and effect bending moments. The goal of wheel to remain on vehicle and to spin at high speed so that
balancing is to reduce vibration. The reduce vibration minimize vibration can be detected by electronic Today’s list of wheel
noise, increase bearing life, decreases operating stress, balancing machine from historical development includes;
consume less energy, increases product quality etc.  Bradshaw’s wheel balancing machine
Balancing is accomplished by reducing the centrifugal  Centrematic balancer for car wheel
forces by aligning the principal initial axis with the geometric  The pocket wheel balancer
axis of the rotation through the adding or removal of materials. Following the growth of technology now, there are now
[1] companies whose job is mainly balancing of machine
components. Such companies have more than fifty balancing

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 Proceedings of Second Shri Chhatrapati Shivaji Maharaj QIP Conference on Engineering Innovations
Organized by Shri Chhatrapati Shivaji Maharaj College of Engineering, Ahmednagar
In Association with Novateur Publications JournalNX-ISSN No: 2581-4230
February, 22nd and 23rd, 2019
apparatus from which each is used to balance a specific job. Considering the size of the machine, the dimension of the
MACHINE ELEMENTS AND FORCES
If the center of gravity of our element of mass m has a maximum balancing weights is chosen. The volume of the
linear acceleration. The force required to produce acceleration cylindrical balancing weight is
is fg = mag and is directed in the same sense as og. If an
element having angular acceleration ω, has a moment of h (2 – r2)
inertia, I= MK2 about the center of gravity, the torque required
to produce angular acceleration is T = Iω. The effect of the
force acting through the center of gravity and the torque =  x 0.094 (0.03152 – 0.012)
can be replaced by applying the force art a point displaced at a
= 0.295309 (8.9225 x 10-4)
distance d, from the centre of gravity such that T = Fd.
= 2.634 x 10 m3
I. OUT OF BALANCE MASSES IN COMMON TRANSVERSE
Since the density of steel = 7680 kg/m3
PLANE
Consider masses …M1, M2, M3 and M4 arranged at radii r1, r2, Density = mass
r3 and r4 at angles 1, 2, 3, and 4 in a common plane. As the
Vol.
shaft rotate out angular speed ω, each mass will pull on the
shaft by a force m1 w2r12, m2w222, m3w32r3, :. Mass =density x vol.

m4w2r4 and directed outward from the centre of the shaft to the =7680 kg/m3 x 2.634 x 10-4 m3

centre of the respective masses. The resultant of the centrifugal =2.20 kg

force can be obtained either by calculation, resolution of forces
2 kg weight =2 x 9.8 = 19.6N = 20N
or by force polygon. If the resultant is mw2r, th4e balancing
force is – mw2r. Since w2 is common to all the forces, the FORCE ANALYSIS ON SHAFT

computation can be carried out with m1r1, m2r2, m4r4. FC = centripetal force

By resolution of force

E4 =m1r1cos1+m2r2cos2+ m3r3cos3 + m4r4cos4 FC = mω2r =m v2

V =m1r1cos1+m2r2cos2+ m3r3cos3 + m4r4cos4 r

:. The magnitude of the resultant force Where, m=total mass in rotation

RF = (H)2 + (V)2 CONCLUSION

Generally all power transmission devices consist of rotating
The angle which the resultant makes with the horizontal is
parts have unbalance present in them. Due to this unbalance
excessive vibration is produced and these vibrations are
 = tan-1 ∑H transmitted to structure and foundation which leads to failure
∑V of machine parts and collapse of foundation. With the use of
dynamic Balancing Machine we are able to estimate the
By polygon of forces, the magnitude and direction of the unbalance in rotating parts and can be removed with the help
of balancing weights ensuring smooth running of machine
various forces are represented with a line, the balancing force
will be the completing line. [3] References
[1] A. R. Chinchilikar, Dr. G. K. Bhagavat And Dr. B. S. Chittawadgi ,
“Design and Development of an Electronic Dynamic Balancing
II. DESIGN CALCULATIONS Machine,” Proceedings of the Indian Division of the Institution of
Electronic and Radio Engineers ( Volume: 5, Issue: 4, , vol. A247,
APPROXIMATE WEIGHT OF THE BALANCE Page(s): 133 - 140, October-December 1967. (references)

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 Proceedings of Second Shri Chhatrapati Shivaji Maharaj QIP Conference on Engineering Innovations
Organized by Shri Chhatrapati Shivaji Maharaj College of Engineering, Ahmednagar
In Association with Novateur Publications JournalNX-ISSN No: 2581-4230
February, 22nd and 23rd, 2019
[2] Chun-Feng Huang, Jian-Hao Hong, and T.-J. Yeh” Balancing control
of a pedaled, self-balanced unicycle for better human-machine
interaction” ” 2012 IEEE/SICE International Symposium on System
Integration (SII)
[3] MIKLÓS T. KONCZ, “Design of a low-cost balancing machine for
the gas turbine of UAVs,” unpublished.
[4] Rajeev Chaturvedi1*, Shree Niwas Sahu2*, A Sekar3*, K.V .Govinda3*,
“Design and Analysis of Vertical Dynamic balancing machine flexure
for satellite balancing,” 5 th International & 26th All India
Manufacturing Technology, Design and Research Conference
(AIMTDR 2014) December 12th–14th, 2014, IIT Guwahati, Assam,
India
[5] Jim Lyons, “Primer on Dynamic Balancing “Causes, Corrections and
Consequences” IEEE Transl. J. Magn. Japan, vol. 2, pp. 740–741,
August 1987
Books Reffered :
[1] Design Data, Data Book of Engineers , Compiled by PSG Collage
ofTechnology, Coimbtore Published by KalakathiAchchagam Article in a
conference proceedings:
[2] R.S Khurmi& Gupta JG 2004.Machine Component Design.Evrasia
Publishing thous (pvt) LMD
[3] Design of Machine Elements by V B Bhandari, Third edition, Published
by McGraw Hill

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