It is an established fact that dynamic behavior of structures changes due to presence of different faults like unbalance, misalignment in them.

In the present day world, with the development of high speed machineries and light weight high rising structures, fault diagnosis using dynamic behavior of different component of the system has gained paramount importance. It has also been realized that the presence of unbalance and misalignment in structures or in machine members leads to operational problems as well as premature failure.

Frequency analysis has always been recognized as the most effective feature of a vibration analysis program because discrete frequencies present in the vibration spectrum can be directly related to geometry of machines and hence to the faulty part. However a frequency spectrum alone can often be misleading it the other components of a vibration signal (waveform, phase, etc.) are not carefully analyzed.

Balancing is the process of designing or modifying machinery so that the unbalance is reduced to an acceptable level and if possible is eliminated entirely.

Unbalance exists in a rotor when the mass centre axis is different to its running centre axis. Practically all newly machined parts are non symmetrical due to blow holes in castings, uneven number and position of bolt holes, parts fitted off-centre, machined diameters eccentric to the bearing locations etc.

Rotors fall into two groups. One is where the rotor is rigid and does not deflect up to and including the operating speed. The other group comprises flexible rotors that bow up to the operating speed. The first deflection seen is a skipping rope effect which means the centre of the rotor at speed moves out from its rotational axis, causing high static unbalance.

Static unbalance is where the mass axis is displaced only parallel to the shaft axis. The unbalance is corrected only in one axial plane. Couple unbalance is where the mass axis intersects the running axis. For example: a disk that has swash run-out with no static unbalance. The unbalance is usually corrected in two planes Dynamic unbalance is where the mass axis is not coincidental with the rotational axis. This unbalance is usually a combination of static and couple unbalance and is corrected in two planes

Removal of material by drilling, milling etc from the heavy position on the component is used to correct the unbalance. Alternatively it can be corrected by adding material to the light position on the component by bolting or welding balance weights to reduce unbalance.

Shaft alignment is the positioning of the rotational centers of two or more shafts such that they are co-linear when the machines are under normal operating conditions.

It directly affects mechanical reliability. The actions of nature can completely destroy any good alignment. Misalignment costs money. Misalignment creates dynamic stresses on adjacent components. These stresses are above what the designer plan for when sizing bearings, shafts and couplings.

It consists of a motor, a flexible coupling and a two rotor shaft. The rotor shaft is supported by two ball bearing .The diameter of the rotor shaft is 20 mm at the supporting point of bearing. Two disks of 106 mm each in diameter and 10 mm each in thickness is mounted on the rotor shaft.

The rotor shaft is mounted over the base plate with help of two bearing at the two ends.
The rotor shaft is driven by 0.25 hp A.C motor .The electric motor was bolted with the base plate with Nut and Bolt arrangement.

The A.C. voltage regulator is used to adjust the power supply so that motor speed can be continuously increased or decreased in the range from 0 to 1446 rpm. Rotors one end is connected to coupling which is again coupled to motor and the other end is free. Dial indicators was used to monitor the alignment condition.

VIBRATION METER STROBOSCOPE PEIZOELECTRIC ACCELEROMETER OSCILLOSCOPE

The bearing rotor system is properly mounted to the foundation plate. Accelerometer is mounted on the bearing housing. Vibration level is measured in both left and right bearing. The alignment is carried out with the help of a dial indicator. Again vibration is taken to verify proper alignment. Unbalance is corrected.

Unbalance

Misalignment

Maximum vibration amplitude at running

Maximum vibration twice the running speed.

frequency.

Radial amplitude of vibration is more. Their will be no phase shift. There will be no temperature rise at the coupling.

Axial amplitude is more. There will be phase shift. There will be temperature rise at the coupling.

Balancing and alignment are the two most common corrective fixes for vibration .The symptoms are not always clear as to which is dominant in a specific case .When both fixes are to be done, a choice then arises on which one to do first. The answer is almost always to align first, then balance in plane .The reasons are simple .Alignment can be done statically without running the machine .Any existing unbalance does not affect the alignment process .Alignment can be accurately performed in the presence of an unbalance condition. The reverse is not true.

MANOJ KUMAR MANDAL, 802056 VIKASH KUMAR SINGH, 802126 ABHIGYAN PRATAP RAO, 802002 ABHINAV SINGHAL, 802005 ATAHAR KARIM, 802029 PARTHO SAROTHI GUPTA, 802066 SHASHANK SHEKHAR, 802098 PRAVEEN KUMAR, 802071 INDERPAL CHABRA, 802047 MANSINGH HANSDA, 802057 JAGADISH BARAL, 902309

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