In this paper, a nonlinear dynamic model of the single-stage reciprocating compressor system with a rub-impact fault caused by subsidence is developed, considering the piston rod flexibility. Meanwhile, different rub-impact scenarios of the crosshead including no corner, a single corner, two opposite corners, and two adjacent corners of the crosshead impacting on the slide, are considered in this model. Numerical simulation results show that the subsidence, time-varying load, and piston rod flexibility have significant effects on the vibration response of the reciprocating compressor system with rub-impact, where the larger the subsidence and time-varying load, the more intense the vibration response. Moreover, compared to the rigid piston rod, the flexible piston rod causes the system to generate stronger shock. In the rub-impact, the crosshead appeared in three different motion modes: noncontact; permanent contact; and collision – and most of the collisions occur in the form of two adjacent corners impacting on the slide. In addition, strange attractors are observed in the phase space trajectories, and the existence of chaotic behavior is verified using the Poincaré section method and maximum Lyapunov exponent method.

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