Biomimicry and topology optimization for adhesive toughness design in bonded heterogeneous films

Heterogeneous films have recently been extensively studied due to their superior material properties compared to homogeneous films. However, studies focusing on the design of heterogeneous films, especially with multi-material phases and structures, have been relatively scarce. This paper presents a bioinspired design methodology aimed at optimizing the mechanical properties of heterogeneous films through the strategic arrangement of stiff and soft material blocks. The heterogeneous film is represented as a composite beam and the interfacial failure process is simulated by a cohesive zone model. Then an optimization algorithm is employed to adjust the distribution of stiff materials within the soft film patch in the heterogeneous film. The results show that a nearly twofold increase in adhesive toughness for the optimized film compared to the original. Further discussions shed light on the energy distribution and variations in the fracture process zone size, providing insights into the observed enhancements. In terms of efficiency, the proposed optimization method distinctly outperforms the greedy method, demonstrating the potential for a more effective and efficient design of heterogeneous films with improved mechanical properties.