Influence of bedding and prefabricated fissure angles on cement-bonded sand 3D-printed brazilian discs: Experimental investigations and PFC modelling

Abstract

Bedding structures significantly influence rock mass deformation and failure, challenging engineering stability. This study aimed to investigate the fracture mechanisms of layered rock masses by examining the effects of bedding and prefabricated fissure inclination angles on the mechanical behavior of layered Brazilian disc specimens. Layered rock-like Brazilian disc specimens were prepared using sand 3D printing technology combined with cement slurry as a bonding agent, enabling precise control of bedding features. Uniaxial compression tests, with a loading rate of 0.3 mm/min, coupled with digital image correlation (DIC) technology, were conducted to capture load-displacement curves and crack propagation processes, with two schemes designed to explore varying prefabricated fissure inclination angles (α) and bedding inclination angles (β). Additionally, the discrete element method (DEM) using Particle Flow Code (PFC) with Parallel Bond (PB) and Smooth-Joint (SJ) models was employed for numerical simulation, with mesoscopic parameters calibrated against experimental data. Results showed that both α and β significantly affected crack propagation and failure modes: increasing α led to a gradual increase in peak strength, with cracks initiating from fissure tips and propagating toward loading points; increasing β caused the failure mode to transition from vertical splitting to bedding-controlled fracture, with peak strength first decreasing, then increasing, and finally decreasing. PFC simulations effectively reproduced experimental load-displacement curves and crack morphologies, confirming numerical reliability. This study demonstrates that sand 3D printing with cement bonding is viable for fabricating layered rock-like specimens, and the combined experimental and numerical results provide insights into layered rock fracture mechanisms, offering references for understanding bedding and prefabricated fissure influences on rock mechanical behavior.

Keywords

bedded rock masses / sand 3D printing / cement slurry bonding / Brazilian disc test / PFC discrete element simulation

References

[1] Shu X-y, Zhu Z-d, Qu Set al.. Anisotropic characteristics and deformation behaviors of layered rocks surrounding tunnel: A review [J]. Journal of Rock Mechanics and Geotechnical Engineering, 2025, 17(12): 8198-8223

[2] Zhang W-b, Xie X-l, Shi D-det al.. Experimental insights into the mechanical properties and constitutive models of coral aggregate seawater concrete mixed with natural aggregates [J]. Journal of Building Engineering, 2025, 107: 112756

[3] Huang L, Chen Z-l, Cai W-jet al.. Study on damage of horizontal layered rock based on conductivity response characteristics [J]. Alexandria Engineering Journal, 2025, 123: 550-558

[4] Song T-x, Zhou Y-y, Chen Tet al.. Prediction of nonuniform large deformation in deep layered rock tunnels: Comprehensive application of data-driven and theoretical models [J]. Tunnelling and Underground Space Technology, 2025, 158: 106448

[5] Liu P, Li S-q, Jin Het al.. Shape parameterization method and hydrodynamic noise characteristics of low-noise toroidal propeller [J]. Ocean Engineering, 2025, 328: 121088

[6] Sun X-m, Wang L, Jiang Met al.. Experimental and numerical study on the mechanical behavior of layered rock anchored by CRLD anchor cable [J]. Engineering Failure Analysis, 2024, 165: 108773

[7] Zhu X-y, Zhang Z-q, Feng Yet al.. Damage mechanism of tunnel base heave under interlayer weakening effect in nearly horizontal layered rock [J]. Tunnelling and Underground Space Technology, 2025, 159: 106439

[8] Fan Z D, Xie H P, Sun Xet al.. Crack deflection in shale-liked layered rocks under three-point bend loading [J]. Engineering Fracture Mechanics, 2023, 289: 109464

[9] Liu X-f, Pan P-z, Su H-jet al.. Effect of lateral pressure on the stability of inclined layered rock tunnel: A 3D-printed model investigation by cement-based materials [J]. Case Studies in Construction Materials, 2024, 21: e03692

[10] Yang S-q, Song Y, Du S-get al.. Experimental study on mechanical and permeability characteristics of rock-cement interface in ultra-low temperature environment [J]. Construction and Building Materials, 2024, 451: 138790

[11] Hu X-y, Huang S-b, Yu S-yet al.. Study on the interaction mechanisms between the fissure arrays and circular tunnels by physical experiment and meshless numerical method [J]. Theoretical and Applied Fracture Mechanics, 2025, 138: 104935

[12] Yu S-y, Hu X-y, Liang Z-lin. Exploring the elliptic fissure cracking mechanisms from the perspective of sand 3D printing technology and Meshfree numerical strategy [J]. International Journal of Solids and Structures, 2025, 310: 113216

[13] Liu X-w, Liu W, Zhang G-qet al.. Studying the tensile mechanical behavior of soft-hard interlayer rock with experimental observation and FEMCZM method [J]. KSCE Journal of Civil Engineering, 2025, 29(5): 100099

[14] Wang F, Liu W, Deng J-get al.. Hydraulic fracture propagation research in layered rocks based on 3D FEM modeling and laboratory experiments [J]. Geoenergy Science and Engineering, 2024, 234: 212670

[15] Zhou Z-q, Gao T, Sun J-wei. An FDM-DEM coupling method based on REV for stability analysis of tunnel surrounding rock [J]. Tunnelling and Underground Space Technology, 2024, 152: 105917

[16] Yang H-h, Wang M-n, Yu Let al.. Failure response and beam effect of bolt reinforced layer: Numerical modelling using FDM-DEM coupling method [J]. Engineering Failure Analysis, 2025, 175: 109562

[17] Tu J-z, Xu N-x, Mei G. A peridynamics modeling approach for pre-cracked rock cracking processes under impact by integrating Drucker-Prager plasticity model and efficient contact model [J]. Journal of Rock Mechanics and Geotechnical Engineering, 2026, 181179-195

[18] Li L-p, Chen X-c, Gao C-let al.. Peridynamics simulating of dynamics crack propagation in rock mass under blasting load [J]. Simulation Modelling Practice and Theory, 2025, 140: 103079

[19] Ning Y-j, Lin X-h, Chen D-yet al.. Study on the applications of different cover methods in numerical manifold method (NMM) [J]. Engineering Analysis with Boundary Elements, 2025, 174: 106192

[20] Zhang Y-s, Zheng H, Lin S. Random structure modeling of soil and rock mixture and evaluation of its permeability using three-dimensional numerical manifold method [J]. Computers and Geotechnics, 2025, 180: 107089

[21] Yu S-y, Ren X-h, Zhang J-xet al.. Numerical simulation on the excavation damage of Jinping deep tunnels based on the SPH method [J]. Geomechanics and Geophysics for Geo-Energy and Geo-Resources, 2023, 911

[22] Yu S-y, Sun Z-h, Yu Jet al.. An improved meshless method for modeling the mesoscale cracking processes of concrete containing random aggregates and initial defects [J]. Construction and Building Materials, 2023, 363: 129770

[23] Yu S-y, Wang J, Gao Yet al.. Effects of fissure properties on the tunnel damage evolutions: Insights from DIC-based 3D printing experiments and meshless numerical simulations [J]. Tunnelling and Underground Space Technology, 2024, 149: 105817

[24] Yu S-y, Ren X-h, Zhang J-xet al.. Simulating the chemical-mechanical-damage coupling problems of cement-based materials using an improved smoothed particle hydrodynamics method [J]. Case Studies in Construction Materials, 2023, 18: e02018

[25] Yu S-y, Ren X-h, Zhang J-xun. Using an improved SPH algorithm to simulate thermo-hydromechanical-damage coupling problems in rock masses [J]. Case Studies in Thermal Engineering, 2023, 47: 103085

[26] Yu S-y, Sun Z-h, Qian W-pet al.. A meshless method for modeling the microscopic drying shrinkage cracking processes of concrete and its applications [J]. Engineering Fracture Mechanics, 2023, 277: 109014

[27] Yu S-y, Zhou Y, Yang Jet al.. Hydraulic fracturing modelling of glutenite formations using an improved form of SPH method [J]. Geoenergy Science and Engineering, 2023, 227: 211842

[28] Yu S-y, Yu J, Sun Z-het al.. Numerical investigation and experimental study on fracture processes of central flawed sandstone Brazilian discs [J]. International Journal of Solids and Structures, 2023, 262–263: 112054

[29] Yu S-y, Yang X-k, Ren X-het al.. Shear damage simulations of rock masses containing fissure-holes using an improved SPH method [J]. Materials, 2023, 1672640

[30] Yu S-y, Ren X-h, Zhang J-xun. Modeling the rock frost cracking processes using an improved ice - Stress - Damage coupling method [J]. Theoretical and Applied Fracture Mechanics, 2024, 131: 104421

[31] Jia Q-j, Liu X-m, Tan X. Crack evolution mechanism of stratified rock mass under different strength ratios and soft layer thickness: Insights from DEM modeling [J]. Soils and Foundations, 2024, 646101534

[32] Huang L-k, Dontsov E, Fu H-fet al.. Hydraulic fracture height growth in layered rocks: Perspective from DEM simulation of different propagation regimes [J]. International Journal of Solids and Structures, 2022, 238: 111395

[33] Zheng Z, Li S-x, Zhang Qet al.. True triaxial test and DEM simulation of rock mechanical behaviors, meso-cracking mechanism and precursor subject to underground excavation disturbance [J]. Engineering Geology, 2024, 337: 107567

[34] Zheng Z, Tang H, Zhang Qet al.. True triaxial test and PFC3D-GBM simulation study on mechanical properties and fracture evolution mechanisms of rock under high stresses [J]. Computers and Geotechnics, 2023, 154: 105136

RIGHTS & PERMISSIONS

Central South University