Charpy impact test analysis with steel ball via programmable logic controller

Abstract

This paper presents the development of an automated impact testing system based on the Charpy method, using a steel ball as the impact body and a Programmable Logic Controller (PLC) for control and data acquisition. The proposed system aims to provide an affordable, reliable, and high-repeatability solution for the characterization of ceramic materials, whose impact resistance evaluation presents specific challenges in traditional methods. The methodology included the development of the mechanical device, the integration of the PLC and HMI, the programming of routines to calculate the coefficient of restitution based on the sound detection of the ball's impact and rebound, and the comparison of the results with reference data provided by the Ceramic Center of Brazil (CCB). The results demonstrated excellent agreement with the coefficient of restitution values provided by the CCB for different ceramic products, showing close averages and consistently low standard deviations (0.00 to 0.02), which confirms the high repeatability and precision of the developed system. Furthermore, automation allowed for the elimination of human variability and ensured rigorous control of testing conditions, such as drop height and precise detection of the moment of impact. It is concluded that the proposed system is technically effective, economically viable, and suitable for both academic use and industrial quality control laboratories, representing a modern alternative for mechanical impact tests on brittle materials