Abstract: To prepare samples with the same lithology, surface morphology and mechanical characteristics as those of natural rock structural planes, a new method was proposed to originally reproduce rock structural planes by integrating 3D scanning and 3D carving techniques. Marble structural plane samples with the same natural surface shape were made using this new method. Shear tests were carried out on the prepared samples at different normal stresses. In addition, the acoustic emission (AE) technique was used to monitor failure processes of marble structural planes. The results indicate that the reproduced samples are accurately similar to the original samples with natural structural plane. The curves of shear stress and shear displacement can be divided into sliding type and cutting type. The shear failure structural plane can be categorised into dilatancy zone and abrasion zone. A new formula of shear strength is put forward, and theoretical values are in good agreement with experimental results. The change laws of shear stress and AE energy rate, count and hit with time are consistent, and the location of AE events is similar to the asperity damage positions during the shear test.

Key words: 3D scanning, 3D carving, a new method to originally reproduce rock structural plane, direct shear test, strength characteristics, dilatancy characteristics, acoustic emission