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ABSTRACT
Today, high speed machining has become a fact of life for many machine
shops. In industries tool and machine technology has advanced to allow increasingly
higher spindle speeds, one clear benefit of this trend is greater efficiency and greater
tools like breaking, vibrating have face unbalancing etc, therefore for overcoming all
these problems the balancing in essential plays a very important role in producing
quality parts.
INTRODUCTION
starting point, speeds of 30,000 rpm are common and some spindle approach 1,00,000
rpm also.
milling softer metals or composite materials, as spindle speeds continue to increase the
potential, the adverse effect on machine and w/p increases due to vibration increase
exponentially because centrifugal force increases with square of speed. One of the
than expectation one clear benefit of this trend is greater efficiency and productivity
through increasingly higher spindle speeds. As spindle speeds continue to increase the
potential for adverse effects on Machine and w/p due to vibration increases
exponentially because centrifugal force increases with square of speed. One of the
Unbalance defined :-
UNBALANCING TOOL
use balanced or balanceable toolholders. One of the issues is obviously cost. Balanced
toolholders are more expensive than non-balanced, and balanceable toolholders are the
most expensive. However, the technical issues should override the short-term cost
concerns. If balancing (of any kind) is not considered solely on the basis of the cost of
the toolholder, and balancing is in fact required, the ultimate cost will be much greater.
This will lead to out-of-specification parts, extensive downtime of the machine, and
other hand, a long boring bar in a CAT 50 holder might require balancing at 5,000 rpm.
For most applications, 10,000 rpm is still the threshold at which to consider balancing.
For small, relatively simple tools such as endmills and drills, balanced toolholders will
suffice up to about 15,000 rpm. Above 15,000 rpm, the force generated by even the
small amounts of unbalance created by endmills and drills will generate enough force to
Furthermore, at speeds below 20,000 rpm, only relatively long tools will require two-
plane balancing. Above 20,000 rpm, two-plane balancing should be considered for all
applications. Remember, these guidelines are suggestions only. For your specific
requirements, you should discuss the balancing aspects with a toolholder or balancing
specialist.
Balance Tolerance
In North America, the convention is to balance to what is known as ISO Quality Grade
G2.5. Briefly, this means the toolholder balance is consistent with the spindle as
a function of the weight of the assembly and its maximum rotational speed. This value
BALANCING THEORY
Unbalance in a rotating body is defined as the condition that exists when its
principal mass, or “axis of inertia, ” does not coincide with its rotational axis.
STATIC UNBALANCE
F1 = F2
∠ F1 = ∠ F2
The mass axis does not coincide with the rotational axis, but is parallel to
it (figure 1). The force crated by this unbalance is equal in magnitude at both ends of the
rotating body, as is the force vector’s angular position at both of the bearing journals.
Couple Unbalance
COUPLE UNBALANCE
F1 = F2
∠ F1 = ∠ F2 + 180º
The mass axis does not coincide with the rotational axis, but intersects it at the
rotating body’s center of gravity (fig.2)/ The force vectors are equal, but 180º apart.
DYNAMIC UNBALANCE
F1 ≠ F2
∠ F1 ≠ ∠ F2
The mass axis doesn’t coincide with the rotational axis, is not parallel to it, and
m
r
M w
VARIABLE BALANCING
M = Rotor mass
S = Center of mass
w = Angular velocity
u = Rotor unbalance
Couple Unbalance
To find the amount of centrifugal force produced by a given unbalance, use the formula:
F = U x W2
Where W is given as the angular velocity in radians/sec. To fine W, use the formula;
2π × rpm
60
2π × rpm
Combining formulas, we get; F = m×r ×
60
increases at the square of the speed. This is important to remember as cutting speeds
rise. Even if a tool holder has low unbalance initially, unbalance becomes significant
For low –speed machining operations involving spindle speed of less than
10,000 rpm balancing isn’t important factor, unless tool holders are extremely
asymmetrical.
mm. It produces a radial force of only 0.56 lbs, at 15,000 rpm. But most tool holders
aren’t balanced to such stringent values. Research has shown that the average initial
unbalance for most tool holders is 250 g-mm. At 15,000 rpm, 250 g-mm produces a
EFFECTS
Unbalance can have a detrimental effect on both the work piece and the machine
tool. Tool holder unbalance primarily causes chatter. This degrades work piece finish
because vibration makes the cutting tool deviate from its intended path. Close
Unbalance can have even more devastating effects on the machine tools. The
high centrifugal forces generated can cause the spindle to experience tremendous
internal stress, leading to premature bearing failure. Repairs are time consuming and
costly.
Finally, unbalance reduces tool life. A balanced tool holder, can increase tool life
by as much as 50 percent.
This aluminum work piece illustrates tool holder unbalance affecting surface finish.
SOURCES OF UNBALANCE
Hofmann Corp. tested a variety of tool holders. The researchers found that because of
the strength tool holders need to withstand the forces encountered during metal cutting,
they can be classified as rigid rotor. A tool holder that’s strong enough to support a
cutting tool in operation is stiff enough to prevent flexing. Right rotors don’t suffer from
Tests also revealed that couple unbalance usually isn’t serious problem. Most
couple unbalance results from two parts being attached with their axes misaligned. For
example, a flywheel which is not perpendicular to its shaft will have high couple
unbalance. Tool holder, however have tapers that align precisely with spindles. All
Most tool holders tested exhibit high static (single-plane) unbalance. This
unbalance could be traced to several different sources. On CAT V – flange tool holders,
the most common source is the different depths of the drive slots, which is part of the
inherent design.
Some end mill holders have setscrews that cause unbalance. In other cases
The primary recurring source of unbalance in high-speed tool holders, how ever
comes from the collet and or collet nut. Tests have shown that a tool holder that is
perfectly balanced with the tool in place and collet nut properly tightened can be thrown
off balance simply by loosening and retightening the collet nut. As much as 30 g-mm of
unbalance can be introduced this way. Because balance tolerances usually range from 2
tool holders American Hofmann tested displayed a significant amount. Most high-speed
tool holders with two plane - Unbalance have a high length to diameter ratio. They hold
the collet far enough away from the V- Flange. (Usually two or more diameters) to crate
unbalance sources in two distinct planes. This is especially true on CAT V- flange tool
holders, unless the inherent unbalance has been rectified in the tool design.
Even if the tool holder is balanced, the cutting tool itself can cause unbalance.
Tests indicated that unbalance in end mills as small as 0.375” dia. can put a 5 –1 b. tool
holder out of tolerance. Tool unbalance can result from flat son the shanks, varying flute
lengths on the same tool, and nonsymmetrical shapes, like that of boring bar.
CORRECTION
from the unbalance location or “heavy spot,” by drilling, milling or grinding. This is not
practical with a tool holder, as it would have to be remachined after every tool change,
six equally spaced holes in the tool holder’s V-flange area. A setscrew is inserted into
each hole, which usually has either 6 – 32 or 8 – 32 threads. The tool holder is balanced
by turning the screws in or out to create a force vector 180 o from the unbalance force
vector. Extra screws can be added to correct extreme unbalance. The tool holder can
easily be rebalanced when the cutting tool is changed. The setscrews are held in position
with a non- hardening-locking compound. Nylon- insert lock screws also can be used.
This strategy can be applied by users to balance their existing tool holders.
Bench top tool holder balancers such as Hofmann’s MT – 50 enable tool room and setup
unbalance. One has designed a system, which integrates two adjustable rings into the
body for the tool holder. Each ring has equal unbalance. During setup the rings are
placed with their unbalance masses 180o apart. After the tool is installed, the rings are
adjusted until they produce a force vector equal to and opposite the unbalance vector.
Another manufacturer employs a method whereby small weights are placed into
one or more of several equally spaced pockets near the V – flange. These pockets are
sealed after the proper weight has been added to balance the tool holder/
One swiss firm builds a micrometer adjustable boring ban that incorporates an
internal counterweight. As the cutting tool is moved readily, the counter weight moves
BALANCE TOLERANCE
A final consideration is balance quality, or what level of unbalance is acceptable.
The American National Standards Institute’s standard for Balance Quality of Rigid
Rotating Bodies(s. 19 – 1975) defines the permissible residual unbalance for rotating
body relative to its maximum service speed. The standard assigns different balance –
quality “grades” to related groups of rotating bodies based on experience gained with
The balance – quality grade (G) equals the specific unbalance (e) the rotational
U
e =
M
As shown earlier
U or U
G = x W G =
M M
9 .5 x M x G
U =
rp m
The ANSI tables show balance quality for machine tool drives is G 2.5, and for
grinding machine drives, G 1.0. A tool holder’s balance quality should fall between
these limits. It would serve no practical purpose for a tool holder to be balance better
Using the ANSI limits for machine tool and grinding machine drives, we can
calculate the balance tolerance for a tool holder of a given weight operating at
U 9 .5 x 3 0 0 0 g x 2 .5 m m /s e c
(u p p e r) =
2 5 ,0 0 0
U 9 .5 x 3 0 0 0 g x 1 .0 m m /s e c
(lo w e r) =
2 5 ,0 0 0
The balance tolerance for this tool holder is between 1.14 and 2.85 g-mm
CONCLUSION
As spindle speeds creep higher, the need for balanced tool holders becomes
more acute. When buying tool holders, users should ensure that their vendors offer
balanced products. Companies with small tool holder inventories can have them
balanced by independent balancing services. Firms with large numbers of tool holders
will find it more and more practical to install balancing machinery in their tool rooms.
Whichever course they follow, one thing is certain those old, unbalanced tool holders
REFERENCE
4) Websites :
• www.google.com
• www.mmscuttingtoolszone.com
• www.mmsHighspeedMachiningzone.com
STATIC UNBALANCE
F1 = F2
∠ F1 = ∠ F2
Couple Unbalance
COUPLE UNBALANCE
F1 = F2
∠ F1 = ∠ F2 + 180º
DYNAMIC UNBALANCE
F1 ≠ F2
∠ F1 ≠ ∠ F2
The mass axis doesn’t coincide with the rotational axis, is not parallel to it, and
m
r
M w
VARIABLE BALANCING
surface finish.