Dynamic and static balancing of rolls - how, why and when

Roll balancing is the manipulation of the center of gravity so that it falls along the axis around which it must revolve. If this
condition does not exist, imbalance results and the axis will tend to rotate about the center of gravity, with the journals
tracing some circular orbit. The resultant unbalanced forces are detrimental to the rolls.

Static balancing
If the roll supported without friction will remain at rest whenever the rotation is stopped, all the local irregularities are self-
compensating and static balance exists. If the roll is not static balanced, sufficient weight is added to the "light" side to
bring it into balance. This is usually done by drilling a hole and adding weights prior to covering. Static balance is a simple
adjustment and would suffice if forces of rotation did not interfere.

Dynamic balancing
Although the roll as a unit is statically balanced, it is possible that one end of the roll may have an eccentric center of
gravity if correction has been applied to the opposite end. This cannot be detected by simple static balance, but it will
become noticeable when the roll is speeded up. The resulting oscillation is known as dynamic
balance orcouple or moment unbalance. This produces an end-for-end motion and requires investigation to determine
which end, or both, require counterweighting. It is probable that each end will require its own specific counterbalance, with
the sum of the two again producing static balance. Simple static balance will be satisfactory if the roll operates below 70
percent of resonant speed or 800 surface feet per minute. Dynamic balance can be accomplished by adjusting the center of
gravity of both ends of the roll. The local unbalanced points in the roll then are carried with no external vibration if the roll
is a rigid body.

Whip
In the process or making a straight roll out of a curved pipe or any piece of pipe that is curved or bent, the walls will vary
in thickness along the face of the roll as well as around the circumference. When this roll is statically and dynamically
unbalanced and then speeded up, local conflicts in balance along the face appear with the heavy spots in the shell being
slung further from the center. As soon as the shape of the roll is deformed by is own weight irregularities, the resulting
condition is called whip orkinetic unbalance.

To determine the complex underlying causes of whip requires a painstaking approach and provisions for its correction
made early in the balancing operation. What is called for theoretically is individual correction in every plane wherein
imbalance exists. This being impossible, it can be approached by tentatively locating all counterweights at or near the
nodes which are part way in from each end of the roll face. It is likely that additional weight will have to be located at
intermediate points and the initial weights adjusted to bring about acceptable balance.
 How is balancing done?
The determination of corrective measures for fast running rolls can be time consuming even for an experienced operator.
The time for diagnosis and the time required to install the proper counterweights should not be underestimated. After the
location and magnitudes of the counterweights have been found, their secure attachment may require a day or more. A
flexible roll, for instance, may require drillings in the heads to remove weights or drillings through the heads to insert
weights. If it is the face of the roll, holes must be drilled through the shell for bolting or plug-welding the internal weights
in place. This too is time consuming and requires considerable ingenuity.

Due to the nature of rubber coverings, the roll core should be balanced before any covering is done. After a roll has been
covered it is difficult to attach counterweights securely within the shell. Fine balancing, if necessary, can be done after
covering if only small amounts of weight have to be added or subtracted on the ends. Although it is suggested that drilled
holes in a finished cover can be filled with rubber and vulcanized, this should be avoided,
as it is undesirable. It involves a second cure for the roll and the plugged holes will be visible even though they may give
satisfactory service. In addition to the time of curing, the roll must be set up again for grinding which adds to the cost.

The roll is one part of the balance system

Every portion of a rotating system and its supports has an effect on the balance of that system. This can be in the form of
adding to the undesirable vibration or dampening it out. For this reason, balancing ideally should be done in the machine
where the roll is to be run. Obviously this cannot often be done. It is advisable with all rolls and necessary with larger and
heavier rolls to balance the rolls with bearings installed. After the roll has been finished and it is straight and round, the
fine balance can be accomplished if necessary. Small changes can be made on the roll ends with weights

Measurement of and specification for balance

Rolls that operate at low speed will normally need static balancing only. Static imbalance is expressed in pounds at the
working surface. Readings for such imbalance are so greatly influenced by the amount of friction at the bearing surface
that the amount of static imbalance allowable is not standardized. Dynamic imbalance may be expressed in "ounce-inches"
and is the measure of one or more forces which result in vibration at the ends of the roll for a given speed. The amplitude
of such vibration is normally measured by a recording vibrometer.

For rolls on which dynamic balance is specified, the Rubber Manufacturers' Association industry suggests the maximum
amplitude is .005" at the ends of the roll for a given speed. Rolls requiring closer tolerance should be finally balanced in
their permanent position, since the following factors will influence the dynamic balance:
Bearing tolerance
Natural frequency of the machine in which the roll is to operate
Dampening effect of the machine in which the roll operates
This type of imbalance is influenced by face length and core construction and is due to the deflection of a roll when rotated
at a given speed. This deflection is measured at the center of the roll face while the roll is turning at the specific speed. It
is especially important that deflection be corrected before rubber covering.

NOTES: Rolls which are balanced for a given speed are not necessarily in balance for speeds either higher or lower. Rolls
that are to be dynamically balanced must be accompanied with bearings.