Multiscale Finite Element Analysis of Rubber–Carbon Black Composite Incorporating Interphase Cohesive Elements and Debonding

ABSTRACT This study presents a multiscale finite element analysis (FEA) of rubber–CB composites, with a focus on the interphase region between the rubber matrix and CB particles. A multiscale approach that integrates microstructural details with macroscopic behavior has been employed, allowing for accurate predictions of the composite response to mechanical loads. The model incorporates cohesive elements to simulate interfacial debonding and damage, which are major failure mechanisms in these materials. The analysis begins with the development of representative volume elements (RVEs) for both neat rubber and rubber filled with CB. The Neo‐Hookean hyperelastic model for the rubber, which provides excellent computational efficiency and good accuracy within the examined strain ranges, and a linear elastic model for CB were selected, while the interphase is modeled using traction‐separation relations to account for damage initiation and evolution. Experimental validation shows good agreement between predicted and measured stress–strain responses, highlighting the effects of partial debonding at the interphase. The findings underscore the importance of accurately modeling the interphase to enhance the predictive capabilities of rubber composite performance under various loading conditions. The study revealed that the optimal parameters for predicting stress–strain behavior were a maximum normal traction of 10 MPa and shear traction of 5 MPa, aligning closely with experimental data. Finally, the use of uniaxial tension restricts accuracy; therefore, incorporating multiaxial modeling and advanced experimental methods is essential for more precise validation.