A new rotor–stator rubbing model considering the blade–casing rubbing fault is put forward in this paper. The model couples the rotor together with its suspension (ball or roller bearings), the disk, the (multiple) blades, and the casing. In addition, the influence of the rotor–stator clearance on rubbing forces was considered. It can simulate rubbing faults for single-point rubbing on the casing and complete-cycle rubbing on the rotor. The new rubbing model was applied to the rotor–support–casing coupling model, and the casing acceleration response under rubbing faults was obtained by the time-integration approach. The casing acceleration response, blade tip response, and rubbing force were analyzed. An aero-engine rotor tester, including casing, was used to carry out the rubbing experiment for single-point rubbing on the casing and for whole-cycle rubbing on the rotor. The simulation results were found in highly consistent with the experimental results, which fully verified the effectiveness of the new blade–casing rubbing model.

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