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.

For periodic time-varying systems, a method of parameter identification based on the block-pulse function is presented. Firstly, the state-space equation of the system was expanded using the block-pulse function, then the recursion formula of the parameter identification of a time-varying system was obtained, according to the irrespective and orthogonal characteristics of the block-pulse function. This study provides a wide range of applications by saving time in calculation with a highly accurate method. The parameter identification was carried out by including the numerical simulation model of a three-degree freedom system and the vibration experiment results of an asymmetrical rotor system. The state space wavelet method and EMD method were compared cross-sectionally with the proposed method; this shows that the proposed method is accurate and effective, which makes it valuable in numerous applications. It also has a certain application value for several related projects.