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just how dangerous is that for my headphones? |
It depends on the headphones, and on the amp that the offset is travelling through.
If the amp strips DC, then there is no problem. If not, then you have to consider what the amp does with it. If the amp adds no DC offset of its own (unlikely), it will simply magnify the offset by its gain. You have to consider the entire system gain, including the attenuation from the volume control. For a line level source, the overall system gain might be 1 or less, so the DC offset in that situation would be the same or lower.
Now, in all likelihood, the amp will have its own small DC offsets. If it has a negative DC offset and you run a positive offset through it, they'll cancel out, and leave you with a lower overall offset. But, they can also add, if they're in the same direction, leading to a greater overall offset.
There can be other wildcards in here. For instance, some bass boost circuits will also boost DC voltages (i.e. they have no low-frequency cutoff) so DC can be boosted disproportionately to the majority of the signal. Or conversely, there can be various filtering stages in the amp that reduce DC offset without eliminating it.
Now, to the core of your question: what happens if you put 60 mV into headphones? Think about how headphones work: alternating currents (AC) move the diaphragm back and forth in some analog of the output signal of the amplifier, and this moves air, which you perceive as sound. A DC offset is nothing more than telling the headphones' diaphraghm to go one direction and stay there. The magnitude of the offset tells the diaphragm how far to move. A large DC offset tries to move the diaphragm a longer distance than a small offset, and at some point, the diaphragm can't take the stress, and it breaks down.
That's all for a pure DC offset. If there's an AC component riding on top of the DC, then what you get is that the diaphragm doesn't return completely to its resting point: it's always extending one direction or the other. If the DC offset is high enough, you get something very much like clipping, where the diaphragm can't extend one direction far enough to complete the wave the amp is telling it to try for, and so you get these harsh clicky/crunchy sounds as the diaphragm continuously tries and fails to do what the amp is telling it to do.
Try it with some throwaway headphones some time. It's educational.
How bad all this is depends on the headphones. For Grados, 60mV is a very high fraction of their normal ~300-500mV full-scale signal level. (I mean that for most people, this is their loudest listening level with these headphones.) For some headphones, it takes 2V to make the headphones put out a full rockin' volume level, so 60mV is less significant.