Overdischarge
is a severe safety issue that can induce severe mechanical
failure of electrode materials in lithium-ion batteries. A considerable
volume change of silicon-based composite anodes undoubtedly further
aggravates the mechanical failure. However, the mechanical failure
mechanism of silicon-based composite anodes under overdischarging
conditions still lacks in-depth understanding despite many efforts
paid under normal charging conditions. Herein, we have modeled and
tracked the mechanical failure evolution of silicon/carbon nanofibers,
a typical silicon-based anode, under overdischarging conditions based
on the finite element simulation, with derived optimization strategies
of optimal Young’s modulus and stable microstructure. The severe
contact damage between silicon nanoparticles and carbon nanofibers,
which causes larger shedding and breakage risks, has been found to
contribute to mechanical failure. To improve the electrode stability,
an optimal Young’s modulus interval ranging from ∼75
to ∼150 GPa is found. Furthermore, increasing the embedding
depth of silicon nanoparticles in carbon nanofibers has proven to
be an effective strategy for improving electrochemical stability due
to the faster lithium salt diffusion and more uniform current density
distribution, which was further verified by the experimental capacity
retention ratio of carbon-coated silicon and silicon/carbon nanofibers
(84 vs 75% after 100 cycles). Our results provide meaningful insights
into the mechanical failure of silicon-based composite anodes during
overdischarging, giving reasonable guidance for electrode safety designs
and performance optimization.