Impact Tests Research Articles

Dynamic mechanical properties and damage constitutive modelling of paste phyllite under triaxial impact testing

Dynamic mechanical properties and damage constitutive modelling of paste phyllite under triaxial impact testing

Microstructure Evolution and Cryogenic Impact Toughness Changes in Ce‐Containing Novel Cryogenic High‐Mn Austenitic Steel Weld Metals under Different Heat Inputs

The Ce‐containing novel cryogenic high‐Mn austenitic steel weld metals under different heat inputs are prepared by submerged‐arc welding to provide a satisfactory welding parameter scheme and further optimize its cryogenic impact toughness. The effect of heat input on microstructure, inclusion, and cryogenic impact toughness of weld metals are investigated via optical, scanning electron microscopy, electron backscatter diffraction, electronic probe microanalyzer, and cryogenic impact test. The results show that the dendrite arm spacing, segregation ratio of Mn, Si, and C elements and average effective grain size of the weld metals gradually increase, and the proportion of high‐angle grain boundaries decrease with the heat input increase from 11.91 to 20.24 kJ cm−1. The type of inclusions of weld metal with different heat inputs are all Ce2O3 and Ce2O2S. The number density of inclusions decreases monotonically from 5976 to 4912 mm−2, while the average size increases from 0.32 to 0.45 μm with the heat input increased. The increase in heat inputs consistently decreases the mean cryogenic impact toughness of weld metals from 123 to 102 J. The higher proportion of high‐angle grain boundaries and finer inclusions at lower heat input play the critical role in improving the cryogenic impact toughness.

Advancements in Bamboo-Based Cushioning Material Manufacturing

The study focuses on producing cushioning packaging material from bamboo fibers. The effects of varying the surface treatment duration and the proportions of foaming agents, adhesives, plasticizers, cross-linking agents, and other components were analyzed in terms of foam density, foaming rate, elasticity, and bubble size. The optimal reagents and the ideal ratios for the different components were identified. The parameters for the foaming process were determined based on a high-efficiency, eco-friendly foaming mechanism. Impact testing was conducted to obtain curves for maximum acceleration versus static stress, dynamic stress versus strain, and dynamic buffering factor versus stress. The study examined the dynamic buffering performance as a function of drop height and compared it to other cushioning materials. The findings indicate that at a height of 450 mm, the bamboo pulp product exhibited a lower peak acceleration value than EPE and EPS in the stress range of 2.8-5.4 kPa, indicating superior cushioning performance under these conditions.

Investigation of Impact Behaviour of Sisal Fiber Reinforced Phenol Formaldehyde Composites

Short Sisal fiber reinforced Phenol Formaldehyde resin composites are prepared with varied fiber lengths (5 mm and 10 mm) and for varied weight fraction (20%, 25% and 30%) of the fibers. Here in this work, Sisal fiber is used as reinforcement. Since it is abundantly available in nature and majority of it is getting wasted without being used as reinforcement in engineering applications. Over the last thirty years composite materials, plastics and ceramics have been the dominant emerging materials. The 10 mm fiber length reinforced composite shown improved mechanical properties than 5 mm fiber length reinforced composite. Increase in impact strength is seen when the fiber content in the composite is increased from 20% to 25% and 25% to 30%. The fiber strength, for different fiber lengths and fiber volume fraction, the work of fracture is proportional to the fiber length and fiber volume fraction. Although results show increment in impact strength with fiber volume fraction, proportionality is not demonstrated. This suggests that there are other mechanisms that affect the impact strength of the composites. Crack propagation is the predominant toughening mechanism in notched impact test. Improvement in impact strength characterizes that fibers as stress transferring medium are able to absorb impact energy effectively. Good interaction with crack increases the energy needed for further crack formation and propagation. The exceptional case could be due to low fiber content and relatively short fiber length so that the energy is not dissipated effectively. Weak interfacial bonding of natural fibers is mainly due to incompatibility of hydrophobic matrix and hydrophilic fiber. High moisture absorption causes dimensional changes of natural fibers as well.

Effect of low velocity impact at different temperatures on hybrid adhesives in aluminium-composite single lap joints

This study aims to investigate the effect of a small stone impact on aluminum composite adhesive joints used in aircraft after exposure to various temperature conditions. In this context, single lap adhesive joints were prepared using 2024-T3 aluminium alloy sheets and 8-layer carbon fiber-reinforced epoxy hybrid composite sheets, with epoxy adhesive applied to the bonding surfaces. In addition, different types of hybrid adhesives were developed by reinforcing pure epoxy adhesive with various ratios (1%, 3% and 5% by weight) of graphene doped and undoped Nylon 6.6 (N6.6) nanofibers produced by electrospinning method to reduce brittleness. Low-velocity impact tests of 1.04 m/s under five different temperatures (−50, −20, 0, 23 and 50°C) were applied to all single lap adhesion joints produced and tensile tests were applied to the non-failed specimens to examine the loading conditions after low-speed impact. It was determined that approximately 1.5 J of the 3 J energy given by the low- velocity impact was absorbed in common in all samples, while the remaining part was returned and some separation occurred within the adhesion area due to the effect of this impact. While the low- velocity post-impact tensile strength of pure epoxy resin was measured as 2230.3 N at 23°C and 585.15 N at −50°C, the highest values were obtained in N6.6 reinforced epoxy adhesive with 1%GNP additive, which was measured as 3206.39 N at 23°C and 641.82 N at −50°C, and increased by 43.7% and 9.6% for 23°C and −50°C, respectively. In addition, the rupture surfaces of the specimens destroyed by the tensile test were examined by scanning electron microscopy (SEM) for damage analysis.

Development and Characterization of Mikania, Kapok, Wool, Sugarcane, and Pineapple Fiber Reinforced Polyester Composite

ABSTRACTThis study utilizes plant‐derived fibers including Mikania, wool, kapok, sugarcane, and pineapple as strengthening additions to fabricated and tested reinforced polyester mixtures. This study aimed to examine the mechanical qualities and potential applications of these natural materials in boosting the effectiveness of polyester composites. The composites were formed by including natural fibers into a polyester base using a hand lay‐up preparation method. The finished samples received a complete assessment, covering tensile and impact testing as well as SEM analysis. The findings showed that incorporating natural materials like Mikania vines, wool, kapok fuzz, sugarcane fibers, and pineapple leaves had a notably positive effect on the mechanical features of the plastic composites. The tensile strength of the material combined pineapple was particularly high, achieving a maximum stress of 42.4822 N/mm2 and a maximum stretch of 4.27950%. Similarly, that same composite exhibited a maximum stretch of 3.75753% and a maximum stress of 77.4922 N/mm2 during the bending experiment. The substances exhibiting the strongest impact endurance, as determined by the impact assessment, included kapok, Mikania, wool, pineapple, and sugarcane. The kapok provided an impact toughness of 1.2 N m, which was somewhat elevated. This research offers a precious understanding of using natural fibers as strengthening additives in polyester composites, demonstrating their flexible perspective for many uses. The discoveries present hopeful possibilities for additional examination and progression in composite materials, consequently advancing the development of sustainable materials.

Laser-Induced Decomposition and Mechanical Degradation of Carbon Fiber-Reinforced Polymer Subjected to a High-Energy Laser with Continuous Wave Power up to 120 kW

Carbon fiber-reinforced polymer (CFRP), noted for its outstanding properties including high specific strength and superior fatigue resistance, is increasingly employed in aerospace and other demanding applications. This study investigates the interactions between CFRP composites and high-energy lasers (HEL), with continuous wave laser powers reaching up to 120 kW. A novel automated sample exchange system, operated by a robotic arm, minimizes human exposure while enabling a sequence of targeted laser tests. High-speed imaging captures the rapid expansion of a plume consisting of hot gases and dust particles during the experiment. The research significantly advances empirical models by systematically examining the relationship between laser power, perforation times, and ablation rates. It demonstrates scalable predictions for the effects of high-energy laser radiation. A detailed examination of the damaged samples, both visually and via micro-focused computed X-ray tomography, offers insights into heat distribution and ablation dynamics, highlighting the anisotropic thermal properties of CFRP. Compression after impact (CAI) tests further assess the residual strength of the irradiated samples, enhancing the understanding of CFRP’s structural integrity post-irradiation. Collectively, these tests improve the knowledge of the thermal and mechanical behavior of CFRP under extreme irradiation conditions. The findings not only contribute to predictive modeling of CFRP’s response to laser irradiation but enhance the scalability of these models to higher laser powers, providing robust tools for predicting material behavior in high-performance settings.

Comparative Analysis of Mechanical and Morphological Properties of Cordenka and Ramie Fiber-Reinforced Polypropylene Composites

The depletion of conventional materials and their adverse environmental impacts have prompted a shift toward sustainable alternatives in composite materials engineering. In pursuit of this objective, this study investigated the mechanical properties of polypropylene matrix composites reinforced with Cordenka, an artificial cellulose fiber, and compared them to those reinforced with ramie, a natural cellulose fiber. Continuous strand composites were developed using the Multi-Pin-assisted Resin Infiltration (M-PaRI) process. The strands were subsequently sectioned into 15 mm lengths and injection-molded into dumbbell and strip specimens for mechanical characterization. The results showed that 20 wt% Cordenka/PP composites exhibited a tensile strength of 68.7 MPa, 2.04 times higher than neat PP and 1.66 times greater than the 20 wt% ramie/PP composites. Impact testing further demonstrated that Cordenka/PP composites absorbed 2 to 2.5 times more impact energy than ramie/PP composites, regardless of the presence of notches. Fiber length analysis indicated that Cordenka fibers maintained their length beyond the critical fiber length, allowing for efficient stress transfer and acting as a more effective reinforcement compared to ramie fibers, which were below this threshold. Consequently, the Cordenka/PP composites exhibited significantly enhanced mechanical performance. Scanning electron microscopy (SEM) analysis revealed fewer fiber pullouts in ramie-reinforced composites, suggesting superior interfacial adhesion to the PP matrix, although it did not translate to higher mechanical properties. These findings underscore the potential of Cordenka as a sustainable alternative to synthetic, non-biodegradable fibers in PP composites, providing improved mechanical properties and promising prospects for advanced composite applications.

Abstract 4136952: The Clinical Importance of Arrhythmia Notifications During Use of Wearable Cardioverter Defibrillator

Introduction: Wearable cardioverter defibrillators (WCDs) record continuous ECG data for the purpose of delivering treatment for lethal arrhythmias, but occasionally capture non-treatable arrhythmias that may be of clinical value. The purpose of this study was to evaluate the usefulness to health care providers (HCPs) of evaluating and reporting these other recorded ECGs and the impact on additional arrhythmia detection and clinical management decisions. Research Questions: Do clinicians find arrhythmias identified during routine WCD useful? What arrhythmias are observed? Can the identification of these arrhythmias, validation through ZOLL’s Independent Diagnostic Testing Facility (IDTF) and notification to the provider lead to changes in clinical management? Methods: A multi-center, observational study of 52 US HCPs enrolled 474 patients with commercial LifeVest prescriptions and followed them for up to 3 months. All routinely transmitted LifeVest ECG strips (corresponding to Baseline, Patient Initiated, or other automatic event recordings) during this period were analyzed by ECG technicians at the IDTF within ZOLL. These arrhythmias were reported to the HCP who completed a questionnaire assessing the utility (scored 1 to 5) and clinical impact (medication changes, tests, and procedures ordered) of these events. Results: At the conclusion of the study, 22% of patients (105/474) monitored had 112 reportable, unique arrhythmia events that were sent to 34 providers who completed questionnaires regarding report utility and clinical management decisions. A significant proportion of reports led to medication changes (40%), additional testing (32%) and procedural interventions (23%). The average usefulness of the reports was 3.63/5 with atrial fibrillation representing the most common arrhythmia, but many variations of ventricular ectopy were also captured which tended to be more clinically useful and impactful. Conclusions: WCD patients experience a high burden of actionable arrhythmias. Monitoring and reporting these arrhythmias over the course of normal wear provides additional clinical value to providers. Those arrhythmias that lead to changes to clinical management are the most useful.

Improvement of mechanical performance via interfacial strengthening of carbon fiber‐epoxy reinforced hybrid laminate by incorporation of functionalized graphene nanoplatelet interphase

AbstractThis study is an attempt to develop high‐quality hybrid composites via functionalization (for homogeneous distribution) of the graphene nanoplatelets (FGNP) and then doping to carbon fiber reinforced especial aviation epoxy matrix (Araldite LY5052) via vacuum bagging molding (VBM). The utilized materials were characterized by UV–Vis spectroscopy, tensile, impact, hardness tests, and fracture mode analysis using a scanning electron microscope (SEM). The results revealed a 92% (502.5 MPa) and 85% (490 MPa) improvement in tensile strength values by doping the 1 and 1.5 wt% FGNPs, respectively. There was an improvement in impact strength with the addition of FGNP; a 28% (3.23 J/mm2) increase was achieved in the nanocomposite with 1 wt% FGNP added, and there was a decrease again in the nanocomposite with 1.5 wt% FGNP added. However, it was still 12% (2.83 J/mm2) better than the neat composite. In addition, the results of examining the fractured surface structures of the impact and tensile test specimens were compatible with these results. It reveals a significant separation of fiber‐matrix bonds with 1.5 wt% FGNP contribution. While tensile and impact strengths peak at 1 wt% FGNP value and decrease afterward, hardness values increase in parallel with the increase in FGNPs.Highlights Composites were developed by functionalized graphene nanoplatelets (FGNP). The fiber‐matrix interface was strengthened with FGNP interphase. A 92% tensile strength increase was achieved with 1 wt% FGNP additives. 28% in impact strength and 55% in hardness increase by 1 wt% FGNP. The morphology confirmed that the FGNP interphase filled the interface.

Effects on microhardness, tensile strength, deflection, and drop weight impact resistance with the addition of hybrid filler materials for enhancing GFRP composites.

The work evaluated the usage of various filler materials, namely aluminium oxide (Al2O3), magnesium (Mg), and glass powder, in the bidirectional glass fibre reinforced polymer (GFRP) composites. The required samples were fabricated using the hand lay-up technique by varying the filler material proportions from 0%wt. to 7.5%wt., including individual and hybrid mixture combinations. The prepared samples were evaluated for their microhardness, tensile strength, deflection characteristics, and drop-weight impact resistance. It was observed that the optimal addition of individual filler material improved the microhardness and tensile strength more than that of neat composites. In contrast, hybrid compositions at higher proportions exhibited brittleness and lower enactment due to their poor interfacial bonding and particle agglomerations. The deflection characteristics and drop-weight impact tests also showed enhanced stiffness and impact resistance with the addition of hybrid mixtures of filler materials to the composites. The study supports the potential use of adding filler materials to the composites for lightweight structural applications.

Experimental and Numerical Analysis of the Impact Resistance of Polyurethane Foam Aluminum-Concrete Sandwich Structures

The objective of this research paper is to examine the shock-absorption capabilities of sandwich structures that utilize polyurethane foam and aluminum as energy-absorbing materials. A series of drop weight impact tests were conducted on sandwich structures comprising polyurethane foam, aluminum, and concrete. The investigation encompasses variations in the thickness of the polyurethane foam-aluminum absorption layer, the impact height, and different structural combinations, coupled with numerical simulations. Results indicate that as the thickness of the polyurethane foam-aluminum energy absorption layer increases, the energy absorbed by the composite structure also increases. However, the rate of this increase tapers off as the layer thickness continues to grow. The impact height influences energy absorption within a defined range, enabling optimal utilization of the deformation and energy absorption capacities of the polyurethane foam-aluminum layer. Notably, the double-sandwich structure outperforms the single-sandwich structure in terms of impact resistance. The incorporation of the polyurethane foam-aluminum sandwich structure significantly enhances the impact resilience of concrete. Among the tested configurations, the double-sandwich structure composed of polyurethane foam, aluminum, and concrete exhibits the optimal absorption performance. Nevertheless, the layered nature of the structure significantly increases its construction complexity, potentially impacting the practical feasibility of utilizing the polyurethane foam-aluminum-concrete composite structure in real-world applications.

Crack Control in Additive Manufacturing by Leveraging Process Parameters and Lattice Design

This study investigates the design of additive manufacturing for controlled crack propagation using process parameters and lattice structures. We examine two lattice types—octet-truss (OT) and diamond (DM)—fabricated via powder bed fusion with Ti-6Al-4V. Lattice structures are designed with varying densities (10%, 30%, and 50%) and process using two different laser energies. Using additive-manufactured specimens, Charpy impact tests are conducted to evaluate the fracture behavior and impact energy levels of the specimens. Results show that the type of the lattice structures, the density of the lattice structures, and laser energy significantly influence crack propagation patterns and impact energy. OT exhibits straighter crack paths, while DM demonstrates more random fracture patterns. Higher-density lattices and increased laser energy generally improve the impact energy. DM consistently outperformed OT in the impact energy for angle specimens, while OT showed superior performance in stair specimens. Finally, a case study demonstrates the potential for combining OT and DM structures to guide crack propagation along predetermined paths, offering a novel approach to protect critical components during product failure.

Life Cycle Assessment and Experimental Mechanical Investigation of Test Samples for High-Performance Racing Boats

This paper investigates the environmental impact and mechanical performance of two composite sandwich structures, named Series 1 and Series 2, used in high-performance racing boats. Mechanical tests, including four-point bending and drop impact tests, were performed. It was found on a general basis that Series 2 has higher load-bearing capacity and limited deflection. Series 1, which has a higher density, was able to absorb more impact energy but was more susceptible to damage. A Life Cycle Assessment (LCA) was conducted to evaluate the environmental impact associated with the materials, considering also the testing phase, which plays an important role in the life cycle of materials and structures for advanced marine applications. In addition, two performance indexes were introduced to correlate the mechanical and environmental properties of the analyzed materials. This study emphasizes the importance of considering the testing phase in LCA, as the energy-intensive nature of mechanical testing contributes significantly to the overall environmental impact. The introduced indexes allow for a more comprehensive understanding of the balance between mechanical performance and environmental sustainability. The findings suggest a trade-off between mechanical performance and sustainability, calling for further research into recyclable composites and greener manufacturing processes to balance these competing priorities.

Machine learning based segmentation of delamination patterns from sparse ultrasound data of barely visible impact damage in composites

Composite laminates, known for their strength and flexibility, are widely used but can delaminate under certain barely visible impact. Ultrasound Transmission (UT) scans can detect such failures, but the noise in the scans makes automation of delamination morphology challenging. Machine learning could solve this, but it requires substantial training data. Furthermore, given the considerable time and cost of conducting impact tests on composite laminates, such data remains sparse. This study overcomes data sparsity by enlarging UT scan dataset using image augmentation techniques and synthetic data generation methods. A combination of rotation and elastic deformation of real UT images produced augmented data. Synthetic data was generated by mimicking the statistical variations in real data, including delamination length and rotation per ply, and adding gradients to match the original image noise. A U-Net based machine learning segmentation approach was utilized to capture local and global information through a series of convolutions to apply per-pixel classification. Systematic experimentation was conducted to study the influence of adding augmented and synthetic data on segmentation accuracy. The results show that the use of augmented data increases accuracy significantly. With the addition of synthetic data to the augmented data, there is a marginal improvement in accuracy. However, feature edge accuracy is significantly improved. The preliminary results presented here show the promising use of machine learning techniques for complex, non-destructive inspection methods.

Numerical simulation on 90° impact test of aluminium alloy wheel with the effect of tyre

Car wheels are crucial to automobile safety, requiring a rigorous test before production. A 90° impact test simulates the frontal impact and its influences on the wheel structure, replicating dynamic driving conditions. A novel modelling approach is illustrated for the 90° impact test simulation and investigates the feasibility of excluding the tyre. Firstly, the test performs and validates five impact simulations, with the maximum deformation error being 7.04%. Subsequently, with additional tests, the effectiveness of the modelling approach is evaluated. Lastly, the effect of tyres has been analysed from an energy perspective. The results indicate that the tyre significantly influences the simulation results and should be included in the finite element (FE) model, which differs from the 13° impact test.

Impact of Graphene Nano particles on static and dynamic mechanical properties of basalt-glass fibre reinforced epoxy polymer hybrid composites

ABSTRACT This paper investigates the structure-property relationships in basalt – glass fabric reinforced hybrid polymer composites doped with graphene nanoplatelets. Basalt Glass fabrics were reinforced with 0.2 wt.% − 0.8 wt.% graphene using hand layup and compression moulding to fabricate laminated plates. The mechanical, morphological, and thermomechanical properties were characterised using tensile, flexural, impact, SEM, FTIR, XRD, and DMA testing. Results showed that low graphene loadings of 0.2 wt.% − 0.4 wt.% led to small, isolated graphene platelets decorating the basalt fibres. At 0.8 wt.% loading, extensive wrinkling, folding, and stacking of graphene sheets on the basalt was observed. FTIR revealed increasing sp2 C=C vibrations and XRD showed rising graphene peak intensities with higher loadings. While tensile and flexural strengths improved up to 0.6 wt.% graphene due to efficient stress transfer, impact energy increased consistently until 0.8 wt.% graphene owing to reinforcement effects. DMA exhibited enhanced storage modulus and restricted mobility with more graphene. An optimum graphene loading of 0.6 wt.% was found to maximise the mechanical performance through uniform dispersion and strong interfacial adhesion. The results demonstrate that graphene incorporation can substantially augment the strength, toughness, and thermomechanical properties of the composites at appropriate compositions prior to aggregation.

Tribologically enhanced self‐healing hybrid laminates for wind turbine applications

AbstractWind turbines are subjected to extreme weather and load conditions; hence, high strength and impact resistance are required. Furthermore, wind turbine blades can be subjected to impact loads such as bird strikes, resulting in the formation of microcracks. Self‐healing capsules can be used to mend turbine blades for microscale damage. The incorporation of self‐healing capsules may cause a decrease in the mechanical characteristics of the composites prior to impact resistance, which can be compensated for with efficient fillers such as silicon carbide whiskers (SiCw). Thus, a novel hybrid composite structure is examined with the advantage of using a self‐healing mechanism and SiCw reinforcement. Tensile, tribological, and Charpy impact tests were performed to characterize the mechanical and tribological properties, which were supported with microscopic observations. Multiple experimental characterizations were performed to investigate the impact, and the ultimate tensile strength (UTS) and energy absorption capacity of the structure were shown to increase by 32% and 45%, respectively, with the addition of SiCw. The presence of self‐healing agents provides a 5% rise in UTS after enough time for healing following the collision. The structure's tribological performance is improved by 10% in wear resistance and 20% in friction coefficient.Highlights Hybrid laminated composite structure with silicon carbide whisker and self‐healing capsules. Tensile and Charpy impact tests conducted with microscopic observations Increased ultimate tensile strength and energy absorption capacity by 32% and 45%. Tribological improvement by 10% in wear resistance and 20% in friction coefficient.

Investigation of impact of Calotropis procera extract for properties of mild steel in acidic mediums

Mild steel, widely used in gas and oil pipelines, is recognized for its remarkable capacity to absorb both internal and external energy, as well as its high tensile strength. Despite these attributes, the constant exposure to corrosive toxic substances within these pipelines poses a significant challenge. Over time, corrosion weakens the steel’s resilience to impact and increases the likelihood of failure or explosion due to the buildup of fluid pressure. To mitigate this issue, we explored an eco-friendly approach by introducing natural, non-toxic additives derived from the plant Calotropis procera (CP). The goal was to restore some of the steel's lost energy absorption capacity and enhance its resistance to corrosion and fracture.To test the effectiveness of Calotropis procera extract, we conducted weight-loss experiments using API 5L X70 steel in a solution containing 1 mol sulfuric acid and oil. We varied the concentration of CP plant extract in the solution, using 5%, 7%, 10%, and 13% to evaluate its corrosion inhibition properties. Surface examination was carried out using optical microscopy, which confirmed a corrosion inhibition rate of 50% in the CP + H₂SO₄ solution. To further investigate the mechanical performance, we performed Charpy impact tests in the same acidic environment with CP concentrations of 5%, 7%, and 10%. The results revealed that at a 10% concentration of plant extract, the steel exhibited an absorbed impact energy of 278 J, with a corresponding resilience value of 348.325 J/cm². These findings demonstrate the potential of Calotropis procera extract as an effective, sustainable solution for improving the durability of steel used in corrosive environments.

Analysis of failure modes and impact resistance factors of PDC cutters

The service life of PDC cutters directly affects the overall drilling performance. In hard and heterogeneous formations, PDC cutters often fail prematurely due to dynamic impacts, leading to short footage and slow penetration rates. Enhancing the dynamic impact resistance of PDC cutters is crucial for achieving one-run drilling and reducing costs. This paper systematically studies the main factors influencing and optimizing the impact resistance of PDC cutters. First, the failure modes of hundreds of returned PDC drill bits were statistically analyzed, revealing that dynamic impact failure, wear failure, thermal damage, and erosion are the primary failure modes. Among these, dynamic impact failure is the most prevalent, with dynamic impact load being the main cause. Following the successful practices of leading international drill bit companies, a set of dynamic impact test and evaluation devices for PDC cutters was designed, and corresponding testing standards were established. Based on this, 19 types of PDC cutters were tested for impact resistance, exploring the effects of cutter diameter, diamond layer thickness, chamfer, cobalt removal, and cutter design on impact resistance. An optimized design methodology to enhance impact resistance was summarized, leading to the proposal of a new arch-axe cutter design. Indoor impact test data verified the superiority of this cutter. The research results indicate that cutter design (non-standard cutters) can significantly improve the dynamic impact resistance of PDC cutters. Additionally, increasing the cutter diameter and chamfer size while reducing the diamond layer thickness also enhances the dynamic impact resistance of PDC cutters. Through the optimization of the arch-ridge design, the independently developed arch-axe cutter improved the dynamic impact resistance by 106.45% and 71.43% compared to flat circular cutters and axe-shaped cutters, respectively.