Analyzing Insertion and Retention Forces in Cantilever Snap-Fits: A Combined Simulation and Experimental Approach
DOI:
https://doi.org/10.15282/ijame.22.3.2025.3.0960Keywords:
Snap-fits, Insertion forces, Retention forces, 3D printing, Universal testing machineAbstract
Snap-fit joints offer a cost-effective and efficient alternative to traditional joining methods by eliminating the need for external fasteners and adhering to Design for Assembly guidelines. This study examines and optimizes cantilever snap-fits, a popular choice due to their simplicity. The study employs modeling and experimental testing to investigate how major design characteristics affect insertion and retention forces. Sixteen models were created in Autodesk Inventor, 3D printed with ABS material, then simulated using ANSYS. Experimental validation was performed utilising a Universal Testing Machine to quantify insertion and retention forces, and the results were compared to simulations to assess the accuracy of the Finite Element Model. The results show that Model 13 had the maximum force for simulation insertion at 34.346 N, while Model 10 had the lowest at 3.34 N. Model 5 had the largest retention force (39.458 N), while Model 2 had the lowest (1.722 N). Model 13 had the highest insertion force of 32.177 N, while Model 16 had the lowest at 3.234 N. Model 5 had the highest retention value (41.144 N), while Model 2 had the lowest (1.657 N). Model 16 was determined to be the best design, due to its consistently low insertion forces resulting from its longer beam length and higher insertion angle. The evaluation of percentage mistakes, particularly in Model 14 with retention and insertion error percentages of less than 1.2% and Model 15 with less than 2.4%, emphasizes the importance of experimental validation for accurate predictions. This study enhances the understanding of cantilever snap-fit mechanics, simplifying the development of optimized designs for numerous industrial applications by combining simulation and experimental analysis to achieve precise and reliable snap-fit performance.
References
[1] L. P. Rusli, A. F. Luscher, and C. M. Sommerich, “Force and tactile feedback in preloaded cantilever snap-fits under manual assembly,” International Journal of Industrial Ergonomics, vol. 40, no. 6, p. 618, 2010.
[2] A. Demirer Kahraman and F. Kahraman, “Mechanical fastening methods of polymer-based composites”, International Journal of Advanced Natural Sciences and Engineering Researches, vol. 7, no. 10, pp. 234–239, 2024.
[3] A. G. He, H. Li, and K. Jin, “Shape memory polymer actuated hollow snap-fit design analysis,” Materials & Design (1980-2015), vol. 47, p. 539, 2013.
[4] A. Klahn, D. Singer, and M. Meboldt, “Design guidelines for additive manufactured snap-fit joints,” Procedia CIRP, vol. 50, p. 264, 2016.
[5] T. Jeandin and C. Mascle, “A new model to select fasteners in design for disassembly,” Procedia CIRP, vol. 40, p. 425, 2016.
[6] S. Otmani and D.-K. Shin, “Large deformation analysis of a backside-supported snap-fit with nonlinear behavior,” Heliyon, vol. 9, no. 9, p. e19388, 2023.
[7] K. Yoshida and H. Wada, “Mechanics of a snap fit,” Physical Review Letters, vol. 125, no. 19, p. 194301, 2020.
[8] K. Jorabchi and K. Suresh, “Nonlinear algebraic reduction for snap-fit simulation,” Journal of Mechanical Design, vol. 131, no. 6, p. 061004, 2009.
[9] J. Krzywański, M. Sosnowski, K. Grabowska, A. Żyłka, L. Lasek, and A. Kijo–Kleczkowska, “Advanced computational methods for modeling, prediction and optimization—A review,” Materials, vol. 17, no. 14, p. 3521, 2024.
[10] X. L. Guo and B. H. Sun, “Assembly and disassembly mechanics of a cylindrical snap fit,” p. 2022010076, 2022.
[11] J. J. Singh, J. S. Mehta, R. Kumar, and G. Sapra, “FEA simulations of lower limb prosthetics,” in IOP Conference Series Materials Science and Engineering, IOP Publishing, p. 12030, 2022.
[12] F. Erdemir and M. Özkan, “Application of Taguchi method for optimization of design parameters in enhancement the robust of ‘C’ type snap-fits,” Journal of Polytechnic, vol. 25, no. 3, p. 1385, 2022.
[13] A. R. Moghrabi, S. A. Bhat, P. Szczuko, R. A. AlKhaled, and M. A. Dar, “Digital transformation and its influence on sustainable manufacturing and business practices,” Sustainability, vol. 15, no. 4, p. 3010, 2023.
[14] L. Zhou, J. Miller, J. Vezza, M. Mayster, M. Raffay, Q. Justice, et al., “Additive manufacturing: A comprehensive review,” Sensors, vol. 24, no. 9, p. 2668, 2024.
[15] R. T. Mushtaq, A. Iqbal, Y. Wang, M. Rehman, and M. I. Petra, “Investigation and optimization of effects of 3D printer process parameters on performance parameters,” Materials, vol. 16, no. 9, p. 3392, 2023.
[16] H. Salmanzadeh and M. Rasouli, “The influence of effective factors on mechanical stress on fingertips during snap-fit assembly,” Iranian Rehabilitation Journal, vol. 13, no. 3, p. 39, 2015.
[17] J. L. Amaya, E. A. Ramírez, G. F. Maldonado, and J. Hurel, “Detailed design process and assembly considerations for snap-fit joints using additive manufacturing,” Procedia CIRP, vol. 84, p. 680, 2019.
[18] S. S. Suzamri and M. N. O. Zahid, “Insertion force in snap-fits assembly based on different design parameters: A simulation study,” in Lecture Notes in Mechanical Engineering, p. 991, 2021.
[19] Ji, K.-M. Lee, and S. Zhang, “Cantilever snap-fit performance analysis for haptic evaluation,” Journal of Mechanical Design, vol. 133, no. 12, p. 121004, 2011.
[20] P. R. Bonenberger, The First Snap-Fit Handbook. Carl Hanser Verlag GmbH & Co. KG. 2017. (Original work published 2005)
[21] R. Xu, Y. He, X. Li, M. Lu, and Y. Chen, “Snap-fit mechanical metamaterials,” Applied Materials Today, vol. 30, p. 101714, 2022.
[22] A. Arivazhagan and S. H. Masood, “Dynamic mechanical properties of ABS material processed by fused deposition modelling,” International Journal of Engineering Research and Applications, vol. 2, no. 3, p. 2009, 2012.
[23] S. Vishwakarma, P. Pandey, and N. Gupta, “Characterization of ABS Material: A review,” Quest Journals Journal of Research in Mechanical Engineering, vol. 3, p. 2321–8185. 2017.
[24] S. S. A. Manan, L. P. Chien, and M. Zahid, “A simulation of insertion and retention forces in cantilever hook snap-fit joint,” IET Conference Proceedings, vol. 2022, no. 22, p. 57, 2023.
[25] M. E. Chenthil, S. S. Praneeth, D. S. Anand, and M. Srikanth, “Universal Testing Machine,” International Journal of Innovative Research in Technology, vol. 9, no. 1, p. 1572-1575, 2022.
[26] S. S. A. Manan and M. N. O. Zahid, “Experimental analysis on retention forces of cantilever hook snap-fits,” in Lecture Notes in Networks and Systems, pp. 361-375, 2024.
[27] S. S. A. Manan and M. Nafis, “A parametric study of insertion and retention forces in cantilever hook,” Journal of Mechanical Engineering and Sciences, vol. 17, no. 1, pp. 9360-9369, 2023.
Downloads
Published
Issue
Section
License
Copyright (c) 2025 The Author(s)
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.
