Analyzing Insertion and Retention Forces in Cantilever Snap-Fits: A Combined Simulation and Experimental Approach

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.