Analysis of Nonlinear Vibration Characteristics and Whirl Behavior of Dual-Rotor Systems with Inter-Shaft Rub Impact

Previous studies on rub-impact faults have mainly focused on the rub-impact between rotors and stators, with less research on inter-rotor rub impact. The impact of inter-rotor rub impact on rotor nonlinear vibration is particularly significant. This study investigates the effects of inter-shaft rub impact on the vibration characteristics and whirl behavior of dual-rotor systems. Initially, a dual-rotor model with inter-shaft bearings is established using the finite element method, and inter-shaft rub-impact forces are derived based on contact mechanics. Next, the system response is solved using the Newmark method. Vibration characteristics are analyzed through Campbell diagrams, 3D waterfall plots, time-frequency domain plots, and steady-state rub-impact force plots. Finally, the influence of inter-shaft rub impact on the whirl behavior of the dual-rotor system is studied based on the theory of full-spectrum analysis. The study concludes that inter-shaft rub-impact faults shift the system’s resonance points backward, increase harmonic and combination frequency components, and significantly affect the system response under dual-rotor co-rotation. Excessive friction can lead to self-excited vibrations and sudden amplitude increases, particularly in the LP rotor frequency. Additionally, inter-shaft rub impact primarily affects the whirl behavior of the LP-compressor disk1, showing multiple cycles of forward and backward whirl alternation during acceleration due to combined unbalanced and rub-impact excitations.