“TINS Bayer MaterialScience Snap-Fit Joints for PlasticsContents Ce cr era diminishing cross section: optimal “The illustration above shows a photograph of two snap-fit models taken in polarized light; both have the same displacement (y) and deflectve force (P) Top: The cantilever arm of unsatisfactory design bas constant cross section, The non-uniform distribution of lines (Lringes) indicates a very uneven strain in the outer fibers. This design uses 17% more material an exhibits 469 higher strain than the opti smal design. Bottom: The thickness of fit arm decreases linearly to 30% ofthe orig: optimal snap inal cross-sectional area, The stain in the ‘outer fibers is uniform throughout the length of the cantilever A Snap Joints/General + Common features ‘Types of snap joints + Comments on dimensioning B Cantilever Snap Joints + Permissible undercut + Deflection foree, mating force + Calculation examples Torsion Snap Joints + Deflection + Deflection force D Annular Snap Joints + Permissible lereut + Mating force + Calculation example E _ Both Mating Parts Elastic F Symbols Page 2 of 26 ‘Snap Fit Joints for Plastics - A Design GuideSnap Joints General Common features Snap joints are a very simple, economical and rapid way of join-ing two diferent com- pponents. All types of snap joints have in ‘common the principle thal a protuding part ‘of one component, ¢g.,& hook, stud or bead is deflected briefly during the joining opera- tion and catches in depres-sion (undereut) in the mating component, “After the joining operation, the snap-fit fea- tures should return to stress-free condition, ‘The joint may be separable or inseparable depending on the shape of the undercut; the {force required to separate the components varies greatly according to the design. I is particularly important to bear the following factors in mind when designing snap joints + Mechanical load during the assembly operation. + Force required for assembly Pago 3 of 26 ‘Snap-Fit Joints for Plastics -A Design Guide4 ‘Types of snap joints |A wide range of design possibilities exists for snap joins. In view of their high level of flexibility, plastics are usually very suitable materials ‘or this joining technique. Inthe following, the many design possiil. ties have been reduced to a few basic shapes. Calculation principles have been derived for these basi designs. ‘The most important are: + Cantilever snap joints ‘The load here is mainly Nexural + U-shaped snap joints A variation of the canilever type. ‘Torsion snap joints Shear stesses cary the load. + Annular snap joints ‘These aze rotationally sym-merical and involve multixialsteeses, Pago 4 of 26 ‘Snap Fit Joints for Plastics -A Design GuideSnap Joints/General Cantilever snap joints ‘The four cantilevers on the control panel mod Ue shown in Fig. 1 hold the module firmly in place in the grid with their hooks, and yett can still be removed when required. An economical and reliable snap joint can also be achieved by rigid lugs on one side in combination with snap-fiting hooks on the other (Fig. 2). This design is particularly effective for joining (wo similar halves of a housing which need to be csily separated, The positive snap joint illus trated in Fig. 3 can transmit considerable forces. The cover can till be zemoved easily from the chassis, however, since the sap-fit- ting arms can be re-leased by pressing om the two tongues in the direction af the arrow ‘The example shown in Fig. 4 has certain simi- larties with an annular snap joint, The pres- ence of sits, however, means thatthe load is predominantly flexural; this type of joint is therefore classified as a “cantilever atm” for dimen sioning purposes. oatected nid Fig. I: Module for control panels with four cantilever lugs Fig. 2: Cap with two cantilever and two rigid lugs Fig. 3: Separable snap joints for a chassis cover Fig 4: Discontinuous annular snap joint Page of 26 ‘Snap-Fit Joints for Plastics -A Design GuideTorsion snap joints ‘The torsion snap joint ofthe design shown for ‘an instrument housing in Fig. 5 is still uncom- ‘mon in thermoplastics, despite the fact tat it too, smounls o a sophisticated and economical join- ing method. The design of a rocker arm whose deflection force is given largely by torsion of is shal permits easy opening of the cover under a {owce P; the torsion bar and snap-Sting rocker sm aze integrally molded withthe lower par of the housing ina single shot. Annular snap joints ‘A ypical application for annular snap joints is in lamp housings (Fig. 6). Here, quite small ‘undercuts give joints of considerable szength. Fig 6: A continuous annular snap joint offers a semirhermetic seal and is better Jor single assembly applications 7 H 4 4 22 [ 4 4 4 4 LH I SSSSSSSSSSSSSS SN i Torsion bar Pago 6 of 26 ‘Snap-Fit Joints for Plastics -A Design GuideSnap Joints/General A Combination of different snap + The reflector catches a three points on the periphery. Either a snap-fit hook 34 or a pressure point 3b may be chosen here, so that there is polygonal deformation ofthe inner ving of the housing. Joint systems — The watfic tight illus trated in Fig 7 is an example of an effective design for a functional unit. All the compo- nents of the housing are joined together by snap joint Details: + Housing and front aecess door engage at ‘the fulcrum 1a. The lugs Ub (pressure point) hold the door open, which is useful {for changing bulbs. + The cantilever hook 2 locks the door, The ‘door can be opened again by pressing the ‘hook through the slit inthe housing at 2 Housing Reflector Front = Fig. 7: Cross-sectional sketch (above) and photo (below) ofa traf light made of Makrolont polycarbonate. All the components are held together entirely be means of snap joints ‘The lens inthe front door is ether pro ‘duced inthe second of two moldings 4a fo ia glass lens is desired, this can be held by several cantilever snaps 4b ‘The sun visor engages at § like a bayonet catch, Good service-bility and low-cost production can be achieved with carefully thought-out designs such a this. ess door Assumptions The calculation procedures applicable co various types of joints are briefly described fon the following pages, but in such a way as to be as general as possible. The user can therefore apply this information to types of| joints not dealt with directly In all the snap-fit designs that follow, itis assumed intially that one ofthe mating pats remains rigid, This assumption represents an additional precaution against material fal tre, Ifthe two components are of approxi- rately equal stiffness, half the deflection can be assigned to each part. If one compo- ren is more rigid than the other and the foal strength available is to be utilized to the fullest, the more complex proceduss described in Section H must be adopted. What is said in the remainder of the te plastics parts concerned are, for brief peri fods, subjected to very igh mechanical loads, This means that the stress-strain behavior of the material is already outside the linear range and the ordinary modulus of clasticity must therefore be replaced by the brochure takes into account the fact strain dependent secant modulus Page 7 of 26 ‘Snap-Fit Joints for Plastics -A Design GuideCantilever Snap Joints Design Hints Alarge proportion of snap joints are basically simple cantilever snaps (Fig. 8), which may be of rectangular or of a geometrically more complex cross section (see Table 1) is suggested to design the finger so that either its thickness () or width b) tapers fom the root to the hook; inthis way the Joad-bear- ing cross section at any point beare & more appropriate relation to the local load. The ‘maximum strain on the material can therefore be reduced, and less material is needed, Good results have been obtained by reducing the thickness (3) of the cantilever linearly so that ite value at the end ofthe hook is equal o one-half the value atthe root altemativel, the finger width may be reduced to one-quarter of the base value (See Table 1, designs 2 and 3) With the design illustrated in Table 1, the vul- nerable cross section is always atthe root (see also Fig. §, Detail A). Special attention must therefore be given to this area to avoid stress concentration Fig. 9 graphically presents the effect the root radius has on stress concentration, At first lance, it seems that an optimum reduction in stress concentration is obtained using the ratio. Rh as 0.6 since only a marginal reduetion ‘occurs after this point, However, using RY of 0.65 would result ina thick zea a the intersec- tion of the snap-fit am and its hase. Thick sec- tions will usually result in sinks and/or voids ‘which are signs of high residual stress. Fortis reason, the designer should reach a compro- mise between a large radius to reduce stress concentration and a small radius to reduce the potential for residual stresses du to the re ation ofa thick sec-tion adjacent toa thin sec tion, Internal testing shows that the radius should not be Tess than 0.015 in, in any instance, Detail A oo Tensile stress Compressive stress Fig, 8: Simple snap-fting hook Stress concentration factor 02 oa 06 os 10 12 «14 Fig. 9 Eifects ofa fillet radius on stress concentration Page 8 of 26 ‘Snap Fit Joints for Plastics - A Design GuideCantilever Snap Joints Calculations Shape ofthe romsecton DP Type of design fo: Rectangle v = tebe Tee verte ea y= 067 2 i== ty (Permisibie) detetion =" ednDand,deseese to conquer 428 Dafecton ‘orce ‘Subscript numbers in parenthela designate the note to refer to Table 1: Equations for dimensioning cantilevers Symbols Y= (ermisible) defection (undercut B= (permissible) sain in the outer er ths root in fru: Bas able ‘le = percentage/100 (see Table 2) 1 length of ate h thickness at oot b= width at root Es P K = distance between outer fiber and neutral fiber (center of gravity) = seotion modulus Z =e, ‘where I= axial moment of inertia = secant modulus (see Fig, 16) = (petmissible) deflection force = geometric factor (see Fig. 10) Notes 1) These formulae apply when the tensile stress is in the small surface area b, If st ‘cus in the larger surface area a, how ever, and b must he interchanged, 2) Ifthe tensile sess occurs in the convex surface, use K2, in Fig. 10; i it occurs inthe concave surface, use Kl, accordingly. 3) cis the distance between the outer fiber and the center of gravity (neutral axis) in the surface subject to tensile stress 4) The section modulus should be determined for the surface subject to tensile sees, Seetion moduli for cross. section shape type C are given in Fig. 11 Section moduli fr ather basic geometrical shapes ate to’be found in mechanical Permissible stresses are usually more affected bby temperatures than the associated strains. One pref-erably determines the strain associated with the permissible stress at room first approximation, the comps: sperature. Asa sion may be based on this value regardless of the tempera ture, Although the equations in Table 1 may appear unfamiliar, they are simple maniptla- tions of the conventional engineering equa-tions to pu the analysis in terms of permissible stain levels Page 9 of 26 ‘Snap-Fit Joints for Plastics -A Design GuideGeometric factors K and Z for ring segment Fig 10: Diagrams for determining K1 and K2 for cross-sectional shape type C in Table 1. KI: Concave side under tensile load, K2: Convex side under tensile load Doane wae ee Exampl , = 8.75 mm (0.344 in) r= 10 mm (0.394 in) 0= 75° From Graph: Z/r,° ~ 0.0038 25 = (10 mm)? x 0.0038 3.8 mm3 (2.3 x 10° in?) ti ne Fig 11: Graphs for determining the dimensionless quantity (Z/+23) used to derive the section modulus (Z) for cross- sectional shape C in Table 1. ZI: concave side under tensile stress, Z2: convex side under tensile stress Pago 10 of 26 ‘Snap Fit Joints for Plastics -A Design GuideCantilever Snap Joints Fig 12: Undercut for snap joints ses Fig 13: Determination of the permissible strain for the joining operation (left: material with distinct yield point; right: glass-fiber-reinforced material without yield point) Permissible undercut “The deflection y occurring during the joining ‘operation is equal to the undercut Fig 12) ‘The permissible deflection y (permissible undercut) depends not only on the shape but also on the permissible strain for the mate tal used, In general, during a single, brief snap-fiting operation, patally crystalline materials may be stressed almost to the yield point, amor- ‘phous ones up to about 70% ofthe yield strain. (Glass-iberseinforced molding compounds do ‘ot normally have a distinct yield point, The permis-sible strain for these materials in the ‘ase of snap joints is about half the efongation at break (see Fig. 13) Pago 11 of 26 ‘Snap-Fit Joints for Plastics -A Design GuideDeflection force Using the equations given in Table 1, the per ‘missible deflection y can be determined easily even for cross sections of complex shapes The procedure is explained with the aid of an example which follows A particularly favorable form of snap-fitting arm is design 2 in Table 1, with the thickness ofthe arm decreasing linearly to half its initia value, This version increases the permissible deflection by more than 60 compared to & snap-fiting arm of constant cross section (@esign Complex designs such as that shown in Fig. 15 ‘may be used in applications to increase the effec-tive length, Polymers Division Design Engineering Services would be pleased to sssist you in a curved beam analysis if you choose this type of design The deflection force P required to bend the finger can be caletlated by use ofthe equ tions in the bottom row of Table I for cross sections of various shapes Es isthe strain dependent modulus of elastict- ly oF “scant modulus" (ee Fig. 14) Values for the secant modulus for various Bayer engineering plastics can be determined fom Fig. 16. Te strain value used should lays be the one on which the dimensioning ofthe undercut was based, ‘Secant modulus Strain e Fig. Id: Determination of the secant modulus Permissible short term strain limits at 23°C (73°F) Unreinforced Apect High Heat PC 4% Bayblend? — POABS- 28% Makroblend* Polycarbonate 35% Blends Makrolont = PC 4% Glass-Fiber-Reinforced (Glass) Makrolont(10%) PC 22% Makrolon?(20%) PC 20% Table 2: General guide data forthe allowable short-term strain for snap joins (single join - ‘ng operation): for frequent separation and ‘rejoining, use about 60% ofthese values Fig. 15: U-shaped snap-fitting arm for a lid fastening Polyurethane Snap-Fits Snap-fits are possible using certain polyurethane systems. For more information call Polymers Design Engineering at 412-777-4952. Pago 12 of 26 ‘Snap-Fit Joints for Plastics -A Design GuideCantilever Snap Joints ee atotoe® Bayona? olerbonete res cee - se £ [ ox | les i | 2 g 4 \ e 3 al r ca ' ls ag ate i ie ~~ é 2 aad el [ ee ahaa ian t a =F a ee wight ol asa heen to Bara al |, wed 1, . ‘ocr ods Wo APH) ‘Semtnatiha nwo) | f Fig, 16: Secant Modulus for Bayer engineering plastics at 23°C (73°F) Page 13 of 26 ‘Snap-Fit Joints for Plastics - A Design GuideFig. 17: Relationship between deflection force and mating force Mating Force During the assembly operation, the deflection force P and friction force F have tobe overcome (Gee Fig. 17). ‘The mating force is given by: W=Prun(@+p) =P uttne To wtane wt tan a ‘The value for 1 — yi tan @ can be taken dreetly ‘from Fig. 18. Friction coefficients for various materials are given in Table 3. In cate of separable joints the separation force ‘canbe determined in the same way asthe mating force by using the above equation. The angle of inclination tobe used here isthe angle a Pago 14 of 26 ‘Snap Fit Joints for Plastics -A Design GuideCantilever Snap Joints B - ie : an 3 3 e|s Is =| | Te iE i= - 5 f ——s 35 a ea a Zp Angle ofinelinaton a Figure 18: Diagram for determining_w+tan & 1 tana. 012-022 ‘The fguces depend on the relative speed ofthe 020-025 rating parts, the pressure applied and on the 0.25-0.30 surface quality, Friction between two different 020.035, plastic materials gives values equal to or 030-040 slightly below those shown in Table 3. With 0300 0.40-0.50 twa components of the same plastic materi oasoss the frievion coeticent is generally higher. 045-055 Where the factors known, thas been indicat 0.50-0.60 cd in parentheses. 0,50-0.65 0,55-0.60 0,55-0.60 Table 3: Friction coefficient (Guide data from literature forthe cocficients of fiction of plastics on steel) Pago 15 of 26 ‘Snap-Fit Joints for Plastics -A Design GuideCalculation example I snap-fitting hook ‘This calculation is for a snap-fiting hook of rectangular cross section with a constant decrease in thickness from h at the root to h/2 a the end of the hook (see Fig. 19). This is an ‘example of de-sign type 2 in Table 1 and should be used whenever possible to per-mit greater deformation and to save material. Given: 4, Material = Makralon® polycarbonate 19 mam (0.75 in) 9.5 mm (0:37 in) 4 mam (0.094 in) ¢. Angle of inclination (a) = 30" Find: Thickness bat which full deflection y will, ‘cause a strain of one-half the permissible », Deflection force P «©. Mating force W le» ah Fig, 19: Snap iting hook, design type 2, shape A Solution: 4, Determination of wal thickness b Permissible strain from Table 2: e-== 4% Strain required here € = 12-6 = 2% Deflection equation from Table 1, type 2, shape A: ‘Transposing in terms of thickness 24 = 3.28 mm (0.13 in) b. Determination of deflection force P Deflection force equation ftom Table 1, cross section A: From Fig. 16 at € =2.0% B, = L815 N/mm’ (264,000 psi) P=95 mmx (3.28 mm)' 1,815 Nim’ x0.02 6 19 mm =325N (316) ¢. Determination of mating force W Were pttnga I=yane Friction coefficient from Table 3 (PC against PC) «= 0.50.x 12= 06 FromPig 18: #7489 = 1.8 For =06 anda= 30° tan W= 325 Nx 18=58.5.N (13.216) Pago 16 of 26 ‘Snap-Fit Joints for Plastics - A Design Guide b= Lover! y = 1.09 x02 x 19°Cantilever Snap Joints B Calculation example II snap-fitting hook This calculation example is for a snap-fiting hook with @ segmented ring cross section decreasing in thickness from h a the root to h/2 at the end of the hook (see Fig. 20). This is design type 2, shape C in Table 1 This taper ratio should be used when possible to evenly distribute stresses during arm deflection, also reduces material usage. Given: 4, Material = Bayblend® POIABS b Length (1) = 254mm (1030) «. Angle of are (0) = 75° 4 Outer radius (3) = 20 mm (0.787 in) e:Tnner radius (¢) = 175 mam (0.589 in) £, Thickness) =25 mm 0 in) sh) =02=375 Find: ‘The maximum allowable deflection for a snap-fit design which will be assembled and unassembled frequently. — . ‘ 7 cou INE TR Fig, 20: Snap fiting hook, design type 2, shape C Solution: ‘The permissible strain for a one-time snap-fit assembly in Bayblend® resin i 2.5%. Since the design is for frequent separation and rejoining, 60% of this value should be used or € = = (0.6) (25%) = 15% Deflection equation from Table I, type 2, shape C: y= OK ev ‘The variable for Ky can be obtained fom the curves in Fig, 10, Noe tha if the member is delctd o tht he Wns stress cccrs in he conver surlace, the curve for Ky shoul be wid sft ocurein the concave surface, Ky shot he sted. In thi case the tense ses wl ecco the convex surface, therefore the curve for, should be wed s/ty = 0.875 and 0= 75° 26 267) 0015) (25-4 mmy 20mm from Fig. 10, Ka) = y- 164 = 2.11 mm (0.083 in) Alternate Solution: ‘This method may be used as a check or in place of using the curves in Fig. 10, Deflection equation from Table ype 2, shape D: y= 055 € 1’ ‘Tue value for cy whichis the distance from the neta ast the outermost ier, can be calculated fom the equations shown below. erent 2sing U-hn+ 1) o =e sind Uy 2sin gd 34c08 6] 382 hin) ty 34 Use efor cis ifthe tensile stress occurs in the convex side of the beam. Use c; fore ifthe Aensile sess occurs in the concave side. For this particular problem, iis necessary to calculate c eo 520mm yi y7s U-asmm fo ]=252 mm 300654) 20mm = 22.5 mm Solving for y using e yields y=0.55 (0015) (25.4 mm) 252mm Both methods result in a similar value for allowable deflection 11 mm (0.083 in) Pago 17 of 26 ‘Snap Fit Joints for Plastics -A Design GuideTorsion Snap Joints Cc Deflection Inthe case of torsion snap joints, the dele tion is nat the result ofa flexural load as with ‘cantilever snaps but is due toa torsional deformation of the fulerusn. The torsion bar ig. 21) i subject to shear Torsion bar Fig. 21: Snap-fining arm with torsion bar “The following relationship exes beswoen the tal angle of twist and the deflections y, ory (Fig. 2 whee yey * angle of twist sing= TT Yi.¥_ = deflections Ay 1; lengths of lever am ‘The maximum permissible angle gpa is limited by the persmissible shear strain, where 180. Yom pm =Permissible total angle Smt et of twist in degrees Ypm = permissible shear strain 1 = Iength of torsion bar (ald for circular eros section) r radius of torsion bar ‘The maximum permissible shear strain yp for plastics is approximately equal t where Ypm ~Permissible shear strain Yar 1 Gm Gm = permissible stain Yor Gn, y Poisson's ratio(for plastics approx. 0.35) Pago 18 of 26 ‘Snap-Fit Joints for Plastics -A Design GuideTorsion Snap Joints Cc Deflection force Sean te ict ee | ter eee aa Pill=?, Sh (aay where G = shearing modulus of elasticity ‘y= shear stain p= polar moment of inertia xr =: fora solid eiteular cross section ‘Note: Th factor 2 only applies where there are two torsion bars, asin Fig. 21 The shear modulus G can be determined fainly accurately from the secant modulus as follows: g, 6 s © 2s) Example of snap iting rocker arm (flexure and torsion about the ¥ axis) where = secant modulus y= Poisson's ratio Pago 19 of 26 ‘Snap-Fit Joints for Plastics -A Design GuideAnnular Snap Joints D Permissible undercut Detail x ‘The annular snap joint isa con-venient form of joint between two rotationally symmetric pats. Hore, too, a largely stress-free, positive joint is normally ob-tained. The joint ean be either detachable (Figs. 2a, 23), dificult co disassemble or inseparable (Fig. 226) depending on the d-mension ofthe bead and the re-turn angle. Inseparable designs should ‘be avoided in view of the complex tooling required (split cavity mold) ‘The allowable deformation should not be exceeded either during the ejection of the ‘pat from the mold or duting the joining operation ‘The permissible undercut as shown in Fig. 24 is limited by the maxi-mum permissible strain Yo Gad Note: 8 absolute value. ‘This is based on the assumption that one of the mating parts re-mains rigid. If this i not the case, then the actual load onthe material is correspondingly smaller. (With compo- nents of equal flexibility, the strain i halve, ie, the undercut can be owice as large.) W= mating force y= undercut «= lead angle = return angle all thickness diameter atthe joint Fig. 24: Annular snap joint—symbole used separable inseparable Fig. 22: Annular snap joint Pago 20 of 26 ‘Snap Fit Joints for Plastics -A Design GuideAnnular Snap Joints Deflection force, mating force ‘The determination of the mating force W is somewhat more com-plicated for annular snap Joins, Tie is because the snap-fitting bead on the shaft expands a relatively large portion of the tube (Fig. 25). Accordingly, the stress is also distributed over a large area of the material surrounding the bead. Experimentally proven answers to this problem are based on the “theory of a beam ff infinite length resting on a resilient foundation.” Two extreme cases are depicted in Fig. 26, Hoon Fig, 25: Stress distribution during joining operation y Beam Resilient foundation Resilient foundation Fig. 26: Beam resting on a resilient foundation ©The fozce Pis applied atthe end ofthe beam. (This caresponds to. snap jont was he groove at the end ofthe tube) ‘A somewhat simplified version ofthe theory may bbe expressed as follows for joints near the end of the tbe Pay-d-B-X where transverse force undercut diameter atthe joint ES = secant modulus evant modulus geometric factor epee ‘The geomettic factor X takes into account the geometric rigidity [As far as the mating force is concerned, friction conditions ang joint angles must also be taken into ‘consideration ‘extemal diameter ofthe tube Kiameter at the joint @ The force Pis applied a long distance (ca) from the end of the \ beam. (This is equivalent to an annular snap joint with the groove remote ftom the end ofthe tube) ‘The geometvic factor, assuming tht the shaft is rigid and the outer tube (hub) i elastic, is as Pago 21 of 26 ‘Snap-Fit Joints for Plastics -A Design GuideIf te tube ie rigid and the hollow shaft clastic, then where d= diameter atthe joint <= intemal diameter of the hollow shaft ‘The geomettc factors Xy and X,. can be found in Fig. 27 ‘The snap joint is considered "remote" if the distance from the end of the tube is atleast Be isveet where Joint diameter al thickness In this case, the transverse force P and mating {orce W are theoretically four times as great as when the joint is near the end ofthe tube, However, tess have shown thatthe actual ‘mating forces rarely exceed the factor 3 Proms ™ SP Wome SW ‘This means tat if the joint lies be-tween O and 8 minimum, then the factor i between 1 and 3 “The secant modulus E, must be determined as function of the stain e from Fig, 16, For the sake of simplicity t may be assumed here that the stain ‘over the entire wall thickness. (ln fact, it varies at different points and in different directions on the wall cross section) : a a Xw, Me ot Rigid shaft, laste hab 6 a ‘000 a 4 =| Xw : pros Xe Fig. 27: Diagrams for determining the geometric factor X for annular snap joints Pago 22 of 26 ‘Snap-Fit Joints for Plastics - A Design GuideAnnular Snap Joints Fig. 28: Lamp housing with cover Calculation example annular snap joint Given: Lamp cover and housing made of Makrolon* polycarbonate Snap-fiting groove near the end, Dimensions = 200 mm (7.87 in) {£25 mm (0.098 in) for both mating parts x 1 mm (0.039 in) s° “The lead and resum angle is 45°. The edge is rounded, however, andthe effective angle may be assumed tobe «= 30° Required: Occurring sean « Deflection force P Mating force W Lmm* ©=200 mm* 100% “Since both mating parts have approximately ‘equa sifness, the deflection for each part, is approximately lf the undercut. ‘This strain is permissible for polycarbonate according to Table 2 Transverse force P: Pay-dk,-x ‘As the mating parts are of approximately equal stiffuess, the calculation may be performed for either component. In this case ‘he lamp cover (hub) has been chosen Xs from Fig, 27 with y= 200+ 2x25 = 1.025 ¢ 200 Xq =0.0017 = 1.7 x 10° st modulus BS from Fig, 16 2.200 MPa (320,000 psi) {mam x 200 mmm x 2,200 MPa x L7x10°= 748 P=74 N (168 16) Mating force, = 0.6 from Table 3 He tang w THEN x18 1 ytan =1M6N Value 1.8 (from Fig. 18) W = 1,346 N (302.5 1b) The mating and opening force W in this case is a considerable force. It should be remem- bered, however, that such a force would only occur if mating parts in wue axial align-mest were joined by machine. In manual assembly, the greater part ofthe bead is first introduced into the groove at an angle and only the remaining portion is pressed or knocked into position. The mating forces occurring under these circumstances are much smaller, a only part of the bead is deformed, Pago 23 of 26 ‘Snap-Fit Joints for Plastics -A Design GuideBoth Mating Parts Elastic E With all the examples of snap joints men- tioned sofa, the stiffer ofthe two mating parts was assumed to be absolutely rigid. Consequeatly, the more exible of the two com-ponents wae theoretically deformed by the fll amount ofthe undercut ‘Where both parts are deformable, however, the sum ofthese deformations is equal tothe ‘The mating force and the deformations oocur- ring in two flexible mating parts ean be deter sined most simply by using a graph, For this purpose, the transverse force for each component is determined as a function of deflection on the assumption that the other component is absolutely rigid; a "deflective curve” is then plotted foreach mating part as ‘These "deflection curves” are then superims posed (Fig. 28¢), The point of intersection of the two curves gives the actual deflection Torce P and the deflections y; and With the aid of these quantities Fy, and y, the individual strains and the mating force can then be determined without dificulty, as described earlier undercut i, each deformation is smaller. showin Fg. 28a and. 2) Mating part 1 ) Mating part 2 ¢) Mating part 1and $ 3 i : 3 g i : [t & & ; 3 ¥ 0 hy Ay Yih Bay yy 0 Detectony, | Detection, Jon, q_ 12 eaten Detectony, pe €_Detocton y, secon | Fig, 29: Determination of deformation and transverse force when both mating parts are flexible Pago 24 of 26 ‘Snap Fit Joints for Plastics -A Design GuideSymbols F dimensions angle of inclination dimensions a return angle © distance between outer fibre snd nowal ites 8 distance of snap-fiting groove id neutral fit from the end. diameter at the joint «strain 7 internal diameter @m maximum allowable strain i, external diameter Thain at beak modulus of elasticity Gntinsic tangential modulus) yield strain Fy secant modulus angle of twist F friction force y shear stain G shear modulus bh iction coeticient Height thickness atthe root ¥ Poisson's ratio Tp polar moment of inertia P angle of repose K geometric factor for ring stress 8 0 are angle of segment 1 engtb, length of lever arm NN normal force due to insertion P deflection force resultant insertion force r radius t wall thickness WW ating force X geometric factor for annular snap joint index W=shaft index N=hub undercut, deflection Z axial section modulus Health and Safety Information Appropriate literature has been assembled which provides information pertaining to the health and safety concerns that must be observed when handling Bayer prod- cts, appropriate industrial hygiene and other safety precautions recommended by thelr manufacturer should be followed. Before working with any product mentioned in this publication, you must read and become familiar with available information con- cerning its hazards, proper use and handling. This cannot be overemphasized Information is available in several forms, such as Material Safely Data Sheets and Product Labels. Consult your Bayer Representative or contact the Product Safety Manager for the Bayer MaterialScience within Bayer’s Corporate Occupational and Product Safety Department, Bayer MaterialScience LLC, 100 Bayer Road, Pittsburgh, PA 15205 -9741, (412) 777-2000. 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