Fundamentals of balancing

With rotating bodies, imbalance is an omnipresent phenomenon. A typical example are rotating tools on machine tools.

Because unbalance creates a centrifugal force, it increases linearly with the unbalance and squares with the number of rounds. The faster the rotor rotates, the more noticeable the unbalance. But how does unbalance arise, how can it be measured and how can it be eliminated by balancing?

On the following page we have put together the theoretical fundamentals of balancing, the basis for tool balancing.

The centre of gravity of a rotor lies outside the axis of rotation.

• This can also be measured in stationary rotors, e.g. by means of unbalance scales for grinding wheels.
• Upon rotation this causes centrifugal forces perpendicular to the axis of rotation.
• It can be eliminated by balancing in one plane. Any balancing plane can be chosen. Normally there may still be couple unbalance after static balancing.

M_U = unbalance mass (in g)
r = distance of the unbalance mass from the axis of rotation (in mm)
M = rotor mass (in kg)
e = distance of the centre of gravity from the axis of rotation (in μm)
S = center of gravity
F_F = centrifugal force
Value of static unbalance: U = M_U • r = M • e
Unit of unbalance: [U] = g • mm = kg • μm

The centre of gravity lies along the axis of rotation.

• This can only be measured in rotating rotors.
• It causes a moment of tilt during rotation.
• The centrifugal forces of both unbalance masses counterbalance each other (no lateral forces).
• It can only be eliminated by balancing in 2 planes.

M_U1, M_U2 = unbalance masses (in g)
S = center of gravity
r = distance of the unbalance masses from the axis of rotation (in mm)
M = rotor mass (in kg)
F_F1, F_F2 = centrifugal forces
M_U1 = M_U2
F_F1 = F_F2

Combination of static and couple unbalance

• This is the normal case for industrial rotors.

Balancing is used to make compensation for the unsymmetrical distribution of mass in a rotor.
This is possible by:

• applying mass, e.g. a clamped weight to balance car tyres
• removing mass, e.g. by drilling a hole
• adjusting mass, e.g. by adding balancing rings, screws.

Compensation for the static portion of an unbalance

• The centre of gravity of a rotor is brought back to the axis of rotation (eccentricity e=0).
• The couple unbalance of dynamic unbalance remains unchanged.

Complete compensation for unbalance (static and couple unbalance)

• In principle, any balancing planes can be selected (it is best if they are as far apart as possible).

• The tool holder is inserted into the balancing spindle and made to rotate.
• Force sensors measure any centrifugal forces.
• The centrifugal forces are measured in two different planes on the support of the balancing spindle. A sinusoidal signal is produced as the direction in which the centrifugal forces act turns with the spindle. Both the magnitude of the signal and its angle to the spindle must be determined.
• The force signals are used to calculate the balances in relation to the balancing planes. If the position of the balancing planes changes, the unbalances calculated will also change.
• The unbalance compensation is calculated from the unbalance values.

DIN ISO 1940-1 (previously VDI guideline 2060) defines the principles for measuring unbalance
and for balancing. The accuracy of balancing is expressed as balancing quality grade G (previously: Q).

The balancing quality grade is only ever valid for one particular rotation speed of the rotor.

The permissible residual unbalance is calculated from the balancing quality grade, the rotation
speed and the weight of the rotor.

U_per = (G•M)/n • 9549
U_per = Permissible residual unbalance of the rotor in gmm
G = balancing quality grade
M = weight of the rotor in kg
n = rotation speed of the rotor in rpm
9549 = a constant that is produced

In the above example there is a permissible residual unbalance of 1.3 gmm. To illustrate
this value it is useful to convert the unbalance to eccentricity.

In the above example there is a permissible residual unbalance of 1.3 gmm. To illustrate
this value it is useful to convert the unbalance to eccentricity.

U_per = M • e_per
e_per = U_per/M =1.3 gmm/800g = 0.0016 mm = 1.6 μm

Therefore the centre of gravity of the tool holder can be offset by max. 1.6 μm from the axis of
rotation. During balancing the axis of rotation is assumed to be the axis of the taper or HSK.
However, in the milling machine the tool rotates about the axis of the spindle.

Even new spindles TIR of up to 5 μm (equivalent to eccentricity of e = 2.5 μm).

Further example:
Balancing quality G = 1
Rotation speed n = 40.000 rpm
Tool weight M = 0.8 kg
U_per = 0.2 gmm
e_per = 0.3 μm

This permissible eccentricity cannot be achieved in practice.
Even good spindles have a repeatability of 1-2 μm when the tool is changed.
Small amounts of dirt worsen the result significantly.