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 by combining sand 3D printing technology 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. The 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, and then increasing. 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

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Central South University