Precise Replication of Complex Rock Fracture Surfaces Combining 3D Printing, Mold-and-Cast, and Statistical Analysis

It is crucial in geomechanics to understand how fracture surface roughness influences shear failure mechanism, fluid flow, and solute transport through rocks. In this regard, performing identical experiments on fractures poses difficulties due to their inherent heterogeneity and anisotropy. It is challenging to replicate natural rock samples with controlled roughness. This study investigates how artificial rock samples can be generated with controlled roughness (joint roughness coefficient (JRC)), using a combination of three-dimensional (3D) printing and mold-and-cast methods for a specific rough surface as an example. A sample with a certain JRC value using fractal theory was used to create synthetic rough fractures. The fractures were then replicated using 3D printing and concrete molds. Profilometry and photogrammetry were both used to evaluate the accuracy and precision of roughness replication. Both methods …