A novel finite element model is proposed here for predicting the fracture toughness using real microstructural
images and accounting for several parameters that can affect the crack propagation such as filler content, particle
shape, particle agglomeration and particle debonding. The damage energy prior to the catastrophic failure of the
whole microstructure is taken as the energy required for crack initiation, and the fracture toughness is calculated
using the concept of a critical crack size. The predictions agree well with the measured values of the critical
energy release rate at 20 ◦C as a function of both volume fraction and mean particle size. In addition, a para-
metric study showed that an increase in interfacial cohesive energy leads to higher fracture energies at 60 ◦C. The
proposed methodology shows great potential and can be widely applied to other particulate composites, enabling
industry to cost-effectively develop tougher, hence safer and more durable, particulate composites