Shear Mechanism Differentiation Investigation of Rock Joints with Varying Lithologies Using 3D-Printed Barton Profiles and Numerical Modeling

To investigate the shear behavior of rock mass joint surfaces with varying roughness and lithology, this study introduces a novel experimental framework that combines high-precision 3D printing and direct shear testing. Ten artificial joint surfaces were fabricated using Barton standard profiles with different joint roughness coefficients (JRC) and were cast using two representative rock-like materials simulating soft and hard rocks. The 3D printing technique employed significantly reduced the staircase effect and ensured high geometric fidelity of the joint morphology. Shear tests revealed that peak shear strength increases with JRC, but the underlying failure mechanisms vary depending on the lithology. Experimental results were further used to back-calculate JRC values and validate the empirical JRC–JCS (joint wall compressive strength) model. Numerical simulations using FLAC3D captured the shear stress–displacement evolution for different lithologies, revealing that rock strength primarily influences peak shear strength and fluctuation characteristics during failure. Notably, despite distinct lithologies, the post-peak degradation behavior tends to converge, suggesting universal residual shear mechanisms across rock types. These findings highlight the critical role of lithology in joint shear behavior and demonstrate the effectiveness of 3D-printing-assisted model tests in advancing rock joint characterization.