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Contents
1.
Introduction
2.
3.
4
4
both sides
4 4 5
3.3 3.4
Cylindrical snap-fit Ball and socket snap-fit snap-fit joint permissible undercut depth Hmax. and maximum permissible elongation s,^
a
4.
Maximum
6 10 10
4.2
Elastic modulus E
4.3
4.4
angle 2
11
5.
Design calculations for snap-fit joints Barbed leg snap-fit 5.1 5.2 Cylindrical snap-fit
5.3
12
12
13 14
snap-fit
6.
Calculation
6.1 6.2
6.3 6.4
Barbed
examples leg snap-fit Cylindrical snap-fit Ball and socket snap-fit Barbed leg snap-fit supported
on
16
16 16
18
both sides
18
7.
20
8.
21 21 23 24
Barbed
9.
Explanation of symbols
24
10. Literature
25
1.
Introduction
2.
Snap-fits are formfitting joints which permit great design flexibility. All these joints basically involve a projecting lip, thicker section, lugs or barbed legs moulded on one part which engage in a corresponding hole, recess or undercut in the other. During assembly, the parts are elastically deformed. Joints may be non-detachable or detachable, depending on design (figs. 4 and 5). Nondetachable joints can withstand permanent loading even at high temperatures. With detachable joints, it is neces
sary
to test
Snap-fits position.
parts together in a certain important to exclude play between the assembled parts (e. g. rattle-free joints for automotive applications). The axial forces to be transmitted are relatively small. In the majority of appli cations, the joints are not subject to permanent loads
to
two
used
fix
In
some
cases,
it is
in each individual
can
deformation which
unloaded state, snap-fit joints are under little or no stress and are therefore not usually leaktight. By incorporating
Special fasteners such as rivets and clips also work on the snap-fit principle. They should be easy to insert, suitable for blind fastening, require low assembly force and be able to bridge the tolerances of the mounting hole.
sealing elements, e.g. O-rings, or by using leaktight joints can also be obtained.
an
adhesive,
Snap-fits are one of the cheapest methods of joining plastic parts because they are easy to assemble and no additional fastening elements are required.
Hostaform
Acetal
copolymer (POM)
Hostacom
Reinforced
polypropylene (PP)
@Vandar
Impact-modified polybutylene terephthalate (PBT-HI)
lmpet
Polyethylene terephthalate (PET)
registered
trademark
3.
Basic types
of snap-fit joint
The undercut
depth H
outside
edge
edge
of the hole
(% 1):
The parts with an undercut can be cylindrical, spherical or barbed. There are three corresponding types of snapfit
undercut
is deflected
depth H
LI
L2
(1)
joint:
The
leg
by
this
amount
during assembly.
to
Barbed
2. 3.
In
designing a
barbed
at
leg,
care
should be taken
pre
vent
overstressing
as
the vulnerable
therefore be
3.1
large
as
possible.
Barbed
leg snap-fit
3.2
Hg.l
Barbed
3
both sides
Fig.
-\
1, Pj
i
S
(/}
_vu
-1 >~
HJ1
T t
1
l
/R
spring elements supported on one or both sides and usually pressed through holes in the mating part (fig. 1). The hole can be rectangular, circular or a slot. The cross-section of the barbed leg is usually rectangular, but shapes based on round cross-sections are also used. Here, the originally cylindrical snap-fit is divided by one or several slots to reduce dimensional rigidity and hence assembly force (fig. 2).
Barbed
legs
are
This
on
joint employs
barbed
receiving
edge of the barb and the width of (fig. 3). Hence as in formula (1) we
obtain:
undercut
depth
Lt
L2
(la)
This
Fig.2
snap-joint may be detachable or non-detachable depending on the design of the retaining angle.
3.3
Cylindrical snap-fit
Cylindrical snap-fits consist of cylindrical parts with a lip or thick section which engage in a corre sponding groove, or sometimes just a simple hole in the mating part.
moulded
Fig.
4: Non-detachable
joint
^1DG
UG
100%
(4)
elongation (+)
of the hub
e2
+ ~^-WO%
,
AV*
i-TC
(5)
As it is
depth H is appor mating parts, it is assumed for sim plicity that only one part undergoes a deformation e corresponding to the whole undercut depth H.
not
H
s
-100%
or
Dr,
e=^^-100% DK
3.4
snap-fit
Fig.
5: Detachable
joint
Fig.
largest
undercut
depth
H.
snap-fits (fig. 6)
A ball
are
mainly
used
as
motion
undercut
depth H
DG
DK
(2)
DG largest diameter of the shaft [mm] DK smallest diameter of the hub [mm]
The parts
are
depth
DG
DK
(7)
deformed
by
the
amount
of this undercut
depth during assembly. The diameter of the shaft is reduced by ADC, and the diameter of the hub increased by +ZlDK.
So the undercut
depth
H
can
also be described
as
the hub. As
=
change,
the hub is
ADC
JDK
deformed
(3)
the shaft and hub
,
-
as
follows:
As
are
changes,
elongation
DG-DK ^
jL>K
H
100%
=
100%
deformed
follows:
DK
(8)
4.
Critical dimensions
legs
are
stressed
cylindrical snap-fits. As a result of this, higher elongation is permissible and in many cases is necessary for design reasons.
of the type of
non-rectangular barbed leg cross-sections, the follow ing relationships apply between undercut depth H and deformation e in the outer fibre region (outer fibre elon gation):
For
The
load-carrying capacity
of
snap-fits depends
on
the
elastic modulus E and coefficient of friction //. It can be matched to the requirements of the joint by adjusting undercut
semicircular
cross-section
I2
Hmax.= 0.578
r
en
100
(10)
depth
H and
assembly angle
or
retaining
third of
a
angle
K2
I2
cross-section
4.1
Hmax.
0.580
r
en
100
(H)
Maximum
maximum
Hmax.=
0.555-^-^of
an
(12)
In barbed
legs (fig. 7), the following relation applies between undercut depth H (= deflection) as a result of deflection force FB and elongation or compression in the outer fibre region of the barbed leg cross-section (rectangular section):
undercut
These
relationships
also
annulus.
comparison
to
depth Hmax.
-|- - ^
-
(9)
permissible
undercut
depth Hmax.
for barbed
legs
barbed
x.
leg length [mm] barbed leg height [mm] permissible elongation [/o]
7
form of segments of a circle is 15% lower than that of a rectangular barbed leg cross-section (assumption:
-I).
The maximum
Fig.
permissible undercut depth Hmax. for barbed legs of different length and height with a rectangular cross-section can be read off figs. 10 to 13.
Kg-
\
'fi
a
\
Fig.
8:
Elongation
in cross-section A- A
'T
(fig. 7)
n t
1
The maximum barbed
The maximum deformation critical
in the
region
permissible undercut depth Hmax. for leg snap-fits supported on both sides can be calculated with the aid of fig. 14, irrespective of the material. Fig. 14 applies for emax 6% (see calculation example 6.4).
=
Fig.
10: Maximum
permissible
undercut
depth Hn
Fig.
12: Maximum
permissible
undercut de
a
3
o^
~13^
~
max.
2%
s 1=50 mm
s_
<^i
4^
mm
LU u=L
1
E
^|
i"
s,
30
M
^
t
-%
20
y&^
\
s
n *iln*L
max.
8%
N
\
mm
S Is
A
=
Hmax. depth
oj
:
V
\
>
Vl
|5
=
30
mrr [
KJ
x=
N
20
mn
X
s
V
20
mm
10
undercut
\
s
Xj
f p bo \.
s
SJ
= =
^s
15 mm\
10
rn
m\
\
\
Sk
s
N
\.
mmN.
s
1
8
6
Sl=15
s
V
s
s
\
sl
=
10
mm
sv
permis ble
Maximu
x \
v
S.
p^
s\
s
Si
=
op
4*
X 1= 5
s
mm
mi n
\\
Ui
X
V
\
pfo
S
\
I
0 5 0.8
o l^
1.0
2345
6mm8
0.5
0.8
1.0
345
6mm 8
Height
of barbed
leg
Height
of barbed
leg h
Fig.
11: Maximum
permissible
undercut
depth Hn
Fig.
13: Maximum
permissible
undercut
depth Hmax.
mm
10
8 6 5
P^\ y
rr
""
max.
6%
s
\
x\r 30r s
\
on
S
JV
X
s
s. ^V 1
S
=
20
mm
X
X
Si
=
Sj=15mmS \
10
mm
4
3
\ X
I I
0.1
N^
V
S
X
1 1.5
mr n
X
s
Height
of barbed
X
6mm8
X
0.8 1.0
0.5
0.8
1.0
345
6mm8
345
leg h
The undercut
depth H is
calculated
as
follows:
maximum
permissible
undercut
en
depth
DC
(14)
, 12
(-!)' (>+4)
(-1)
leg [mm]
J~lmax.
100
^ ()
Dt
outside diameter of the shaft [mm] in cylindrical snap-fits or ball diameter [mm] in ball and socket
1
s
snap-fits
The maximum definite
Smax.
Fig.
14: Barbed
on
both
as a
function of barb
=
permissible elongation of materials with a yield point (e. g. Hostaform) should be about a third of the elongation at yield stress es (fig. 15a). For materials without a definite yield point (e. g. glass fibre reinforced Hostacom, fig. 15b), the maximum per missible elongation (see table 1) should be about a third of the elongation at break SR.
emax.
6%
with
definite
yield point
os
0.4
relative
0.01
0.2
es 3
El-
0.1
0.08
0.06
definite
yield
0.04
|
TB
e
0.02
0.01
0.008
0.006
IE.
0.004
SR
0.002
Fig.
16
0.001
F ^o
ES
/
'
0.3
0.4
0.5
0.6
-r
With
cylindrical snap-fits
permissible
the maximum
undercut
Table 1 :
Maximum
permissible elongation
emax.
permissible
undercut
depth Hn
Material
Maximum
permissible elongation
emax.
(%)
Barbed
leg
Hostaform C 52021 Hostaform C 27021 Hostaform C 13021 Hostaform C 13031 Hostaform C 9021 Hostaform C 2521 Hostaform C 9021 K
Hostaform C 9021 M
Hostaform C 9021 TF
Hostaform T 1020 Hostaform S 9063/S 27063 Hostaform C 9021 GV 1/30 Hostaform S 9064/S 27064
Hostacom M2 N02 Hostacom M2 N01
1.5 0.8
10
Hostacom G2 N01 Hostacom M4 N01 Hostacom G2 N02 Hostacom Ml U01 Hostacom G3 N01
1.5 1.0
Hostacom M4 U01
Impet
2600 GV 1/30
S 0.5
Vandar 4602 2
^2.0
Celanex 2500
Celanex 2300 GV 1/30
1.0
S 1.0
S 0.5
4.2
Elastic modulus E
The elastic modulus E0 is defined in DIN 53 457 as the slope of the tangent to the stress-strain curve at the
Fig. 17: Secant modulus Es as a function of outer fibre elongation (based on 3-point flexural test) (el%/min)
a
page
8).
Celanex 2300 GV 1/30
Hostacom G 3 N01
E0
at
the
point
(15)
d Hostacom M 4 N01 With greater elongation, e. g. Si (fig. 16), the elastic modu lus is smaller because of the deviation from linearity
a e. corresponds slope of a secant which is drawn from the origin through the e\ point of the stress strain curve. This is known as secant modulus Es and is dependent on the magnitude of elongation e
to e
between
the
and
Vandar4602Z
The
following applies:
Es
=
N/mm2
7500
,a
S,
f(8)
(16)
7000
This
tion
secant
snap-fits.
e
modulus ES is used in design calculations for Fig. 17 plots the secant modulus against elonga
to
6500
up
the maximum
barbed
legs.
\ \
v
450(f
4.3
4000
assembling snap-fits, friction has to be overcome. The degree of friction depends on the materials used for the mating elements, surface roughness and surface loading. Table 2 gives coefficient of friction ranges for various combinations of mating element materials. The friction values quoted are guide values only.
In
\ \ \
3500
\
3000
V
\
vV
2500
S3
"V
2000
Vs sf__ .!^
_\ sjX \ ^ ^1
1
^S
Table 2
1500
[*-_
'
^^^
---^
=
Mating
element materials
Coefficient of friction //
0.2 0.2 0.1 0.4 0.3
to to to to
1000
^s
l"**
*-
25*^.
to
to to
0.3
0.3 0.2
0 500
T
1 1
1
plastics
calculation
example
6.2
3456
Hostacom/other Hostacom/steel
plastics
0.4
0.3 0.3 0.3 0.2
0.2 0.2
0.2 0.1
Elongation
to
to
0.3
0.2
0.4
0.3
plastics
to
to to
0.3
0.3
Celanex/other
Celanex/steel
plastics
to
to
0.3
0.2
10
4.4
at
and
retaining angle
a2
Fig.
18: Detachable
joint
The
(figs.
18 and
barb dimensions and coefficient of friction fj, between the mating elements (table 2), determines the required
(fig. 20). The greater a\ the higher the required. With a large assembly angle and high coefficient of friction //, it may no (! 45) longer be possible for parts to be assembled. The barb then shears off rather than being deflected. The recom mended assembly angle for barbed legs and cylindrical 15 to 30. snap-fits is i assembly assembly
force
=
force F,
Fig.
19: Non-detachable
joint for
90
snap-fits, the assembly angle cannot freely chosen. It depends on the maximum permissible socket opening diameter DK (fig. 27). retaining angle 2 (figs. 18 and 19) decides how much loading the joint can stand. The maximum load-bearing capacity is reached when the retaining angle is a2 90 (fig. 19). During long-term loading and/or in the event of elevated ambient temperatures, the retaining angle 2 should always be 90. The joint is then permanent. For detachable joints, a retaining angle 2 45 should be provided, preferably a2 30 to 45.
=
=
The
Fig.
20
F]
11
5.
5.1
Barbed
leg snap-fit
Fig.
22
The
load-bearing capacity of snap-fits under steady (short-term) stress depends primarily on:
1
.
the mechanical
particularly
stiffness
modulus ES,
2. the
undercut
Load-bearing capacity is
which the
joint
can
stand in the
assembly
the
possible to design the direction of snap-fit assembly right angles to the actual loading direction F during service (fig. 21). Then the load-bearing capacity of the joint is not determined by pull-out force F2 but by the break resistance or shear strength of the vulnerable cross-section. This design technique is most often used with ball and socket snap-fits.
In many cases, it is
at
The
barbed
assembly force FI and pull-out force F2 (fig. 22) legs can be calculated from the formula:
3H
for
Fl,2
H
ES -J
1
1
// +
tan
Ii2
[N]
(17)
jM-tan!^
Es
Fig. 21
J
1
ft
i
2
[mm] [N/mm2] (Fig. 17) moment of inertia [mm4] (table 3) barbed leg length [mm] coefficient of friction (table 2) assembly angle [] retaining angle []
secant
undercut
depth
modulus
The factor
-^
can
be taken
fig.
tr
l-w-tanai.2
23.
Fig.
tan
gl,2
tan
1,2
as a
j
Table 3 Barbed
section
function of
leg
cross-
Moment of inertia
[mm4]
rectangle
semicircle third of
a
^\1 xNSN
b'h3
|2
b
i,p. wnere
h
r
_j
0.110 r4
circle
|>_
^_
0.0522 r4
quarter of a circle
0.0508 r4
15
30
45
60
t
,
90
2
Assembly/retaining angle
12
With the
retaining angle a2 90, the pull-out force F2 is determined by the shear-stressed area and the shear strength TB of the plastic used.
=
Fig.
24
Table 4
Material
The shear
stress
TS is
65 64
65
Ts
[N/mm2]
(18)
71
64
Hostaform C 9021
Hostaform C 2521 Hostaform C 9021 K Hostaform C 9021 M Hostaform C 9021 TF
Hostaform T 1020
Taking into account ultimate tensile strength OR or tensile strength 0B (table 4), the following holds true shear strength
TB
=
for
62 62
64 49 64 110
or
0.6
0.6
CTR
(19) (20)
[N]
TB
OB
F2max.
A TB
rB
(21)
50 5.2 53
42 42
Cylindrical snap-fit
25
Hostaform S 27064
Hostaform S 9064
Hostacom M2 N02 Hostacom M2 N01 Hostacom M4 N01 Hostacom G2 N01 Hostacom G2 N02 Hostacom G3 N01
Fig.
19
33 33 32 70
80
36 33
Celanex 2500
Celanex 2300 GV 1/30 Celanex 2300 GV 3/30 Vandar 4602 Z
65
150
50
40
Impet
2600 GV 1/30
165
I Test
specimen injection
moulded
according to
assembly force FI and pull-out force F2 for cylin snap-fits unlike for barbed legs can only be roughly estimated. This is because the length a (fig. 25) which is deformed during assembly of the parts with consequent increase in assembly force FI is unknown. The length a depends on both the wall thickness of the hub and the undercut depth H. A useful guide to a has proved to be twice the width b of the moulded lip.
The
drical
13
The
assembly
force FI and
pull-out
force F2
can
be calcu
Fig.
26:
ratio
->u r> c Fu-p.rt.IV2b
r
Geometry factor DG Ji
or
as a
function of diameter
f_
M+
DG
tan
DK
1,2
'
rxn
[N]
(22)
joint
pressure
[N/mm2]
DG
b
fj.
ai
outside diameter of the hub [mm] width of the moulded lip [mm] coefficient of friction
(table 2)
y
Between undercut
s
o
^-Es-^
[N/mm2]
[mm]
(23)
DK
1.2
1.5
a
_
depends
on
snap-fit:
L>G
or -pj
UK
mv +
K=
VDGj
1 +1
Fig.
(24)
27
fuy-i loj
Da DG
outside diameter of the hub
[mm]
depth
H is
accommodated
by expansion
walled shafts, the shaft deforms as well but this can be ignored in the case described here. Fig. 26 shows the geo
metry factor K
as a
5.3
snap-fit
In this
design (fig. 27), the assembly angle j and retain ing angle 2 and hence assembly force FI and pull-out
force F2
The
are
the
same.
Table 5
and
1%)
=
-^100% UK
DG
0.07 0.10
1 2 3 4
0.12
0.14
14
To estimate
The
relationship
can
between undercut
pressure p
be described
by
the
T^2
=
fs~
'
DG
+ tan T i l jM-tana
r-Nn
[N]
(25)
undercut socket
secant
rJ'Es'T
tN/mm2]
[N/mm2] DG ball diameter [mm] f deformation length divided by the a DG l ball diameter (table 5) coefficient of friction (table 2) H a. assembly or retaining angle [] (table 5)
p
joint
pressure
DK ES
K
geometry factor
my bJ
K=
+ i
(26)
+1
fAi- 1 iDj
15
6.
Calculation
examples
b) Assembly force FI
For the
assembly
ES J
I3
force FI formula
// + tani
(17) applies:
6.1
Barbed
leg snap-fit
3H
_
\-fjL-
tan 0.1
plates of a time switch are to be detachably joined by two diagonally opposite spacers and two barbed legs. The hole diameter in the top plate is DK 8 mm. The pull-out force F2 required per barbed leg is 50 N. The barbed legs are to be injection moulded
=
0.3
mm
ES
2800 N/mm2
(fig. 17).
mating elements, it is assumed 0.2 (table 2).
=
slotted circular
(fig. 28).
Using table
3
we
cross
Fig.
28
section:
J
So
0.110 r4
0.11
44
28.2 mm4
assembly
F,= FI
=
force FI works
out as
3-0.3-2800-28.2
153 1
0.2 + 0.577
-
0.2
0.577
18.5 N
Each
securing
to
element
comprises
two
each have
be deflected FI
by
=
H. The
37 N.
barbed
element is therefore 2
c) Pull-out force F2
The
a)
b) c)
What should the dimensions of the barbed What assembly force FI is required ?
What
leg be?
pull-out force F2 is calculated in the same way as 45 is substituted for assembly force except that 2 The pull-out force is thus
=
a\.
pull-out
F2
31.6N
outer
elongation
is
pull-out
force of
1 % For the semicircular crossto be emax. section, the following applies using formula (10):
31.6 N
63
pull-out
force of 50 N.
0.578-^-smax.
6.2
r--^The
1 is chosen
to
rubber-tyred
roller is
to
be made in
two
be 15
mm
parts which are permanently joined together (fig. 29). Because of the relatively high stress involved and the fact
0.578
4
-0.01
directly
onto a
H= 0.3mm
DK
2H
8.6
mm.
to
1 mm, the
assembly angle
and the
retaining
b) What assembly
force FI is
required?
angle
16
a2 45.
H
=
tan
permissible
undercut
depth
2
H
-tan
30
0.64
The maximum
is 6max.
=
permissible elongation
to
for Hostaform
2-0.577
4%, according
table 1. b
=
0.55
mm
Fig.
29
The
joint
(23).
P"W
1
E*-i
a
Qil
<f^ K
7r*
0
^
^:
r
3S^
~B
1 Q?
\
With The
^- ^r I" L>G
=
1.5
fig.
26 shows
secant
modulus for
=
emax.
4% for Hostaform
(fig. 17)
So the
is Es
1800 N/mm2.
joint
pressure works
out as
p-0.04.Jff
p
=
20 N/mm2
The
assembly force FI
Fi
=
is
0.2 + 0.577
So the maximum
calculated
can
be
FI
970.8 N
max.
p\
100
c) Pull-out force F2
~
16 100
Hmax.
0.64
mm
DK DK
DG-H
16
-
90, the joint is perma retaining angle 2 nent. The force required to separate the mating elements can be calculated from the shear strength rB and the shear-stressed area A (shear surface).
Because the
=
0.64
mm
15.36
According
mm.
to
formula
is
to
be 15.4
TB
0.6
OB
b) Required assembly
For the
force FI
OB
(table 4)
assembly
F!
=
(22) applies:
tan ! tan !
TB
0.6
62
JT
DG
2b
1
fj, +
TB
37.2 N/mm2
fj.
case
is
assembly angle
=
a\
is 30.
for Hostaform/Hostaform
mating
it
DG b
16 0.55
be /A 0.2 (table 2). The width b of the undercut can be determined from the assembly angle a\ and the undercut
depth
H.
27.6 mm2
17
So
using
formula
ist:
b) Assembly
For
e
=
force FI
pull-out
a
force F2
F2
max.
TB
%, table 5 gives
27.6-37.2 1027N
The deformation
~=
length
to
divided table 5.
0.07
F2max.
according
snap-fit
of the accelerator
the
(JL
0.4
(table 2).
14
=
In
car,
movement to
pedal
is
trans
D For
Y^r"
mitted via
JLG
~5~~
0
1-75 for K
using
formula
(26).
force F2 of at least 100 N. The ball diameter 8 mm, the outside diameter Da 14 mm.
VDj
my + 1
+1
AY.
loj
Fig.
30
14
+ 1
\7.92J
-+1
P1_Y_ \7.92j
K=2.94
According to fig.
G3N01fore
=
17 the
secant
modulus of Hostacom
l%is
Es
The
4400 N/mm2.
joint
pressure
can
be calculated with H
DG
DK
from formula
(23):
a)
How
large
opening
diameter DK be?
P=D~'Es'"K
b)
What
[N/mm2]
1
assembly
or
pull-out
force F2 is
0.1 44007.92
'
obtained?
2.94
18.89 N/mm2
According to table 1 the maximum permissible gation for Hostacom G3 N01 is emax. 1%.
=
The elon
assembly
or
pull-out force
T^-f A.
is then
(formula 25):
tan L
Thus
using
formula
(8)
DG
~
^p-^D-g:-^fc' //tan
1
a_
U T fJ. +
DK
100%
DK
Fi.2
DK
152 N
DG
=
r>
+ 1
100
6.4
Barbed
both sides
DK
0.01 + 1
The
two
DK
7.92
mm
by
box-shaped moulding made be non-detachably joined barbed leg snap-fits supported on both sides (fig. 31).
are to
housing
18
For
an
assumed
Fig.
31
a
spring
element thickness of
3 mm,
spring
/
*-bf
f
3
=
"T"
"rf
0-15 is obtained.
1
V)
El
\\
\ \
1
\
KP
ir
\, l J
1
fig. 14,
an
undercut ratio of
p_r
=
-p
0.019
1
u
1
snap-fit joints
are
0.019
20
be?
0.4
mm
receiving
moulding
20
mm.
The maximum
to
permissible elongation
emax.
according
table 1 is
6max.
6%
Note:
to
be b
mm.
This
gives
--04 '4
~ ~
20
possible flow line in the region of the spring element provide a weak point. By increasing wall thickness at this point, design strength can be improved (see also C.3.4 Guidelines for the design of mouldings in engineer ing plastics, p. 25, no. 18).
could
19
7.
With
cylindrical snap-fits,
a tubular part under com is greater than under tension. The hub of a pression snap-fit (fig. 32a) is generally easier to demould than the
The undercut
has
to
be demoulded after
portant question here is demoulded or whether it is necessary to bed the under cut in slides, followers or collapsible cores.
snap-fit depends injection moulding. The im whether the parts can be directly
parting line of the mould can run through an undercut edge, for example with a through hole and inwardly projecting lip (fig. 32a) or with an outwardly projecting lip (fig. 32b).
shaft. In
some
cases,
the
In the
more
frequent
case
of
blind hole
(fig. 33),
the
inner and
outer
must
be demoulded
There is
this. The maximum per missible deformation values quoted in table 1 can of
no
general
answer to
cylinder
It takes
1 is
core
course
be
ing.
Problems
well
demould-
3.
reached
(B).
deformation forces into the component. These can result in local stretching of the part or cause the ejector to press
into the part, among other undesirable consequences. A disadvantage here is that the demoulding temperature is
Through further movement of the ejector, the cylinder is stripped from the core. Expansion of the hub by an amount corresponding to undercut depth is not pre vented (C).
rial stiffness is
and hence
mate
Fig.
32
Fig.
33
plastic part
A
<
split core
\\\\\\\\\\
* ^
plastic
part
20
8.
8.1
Applications
Barbed
assembly, particularly
are
in
mass
considerably production.
cars.
Nos. 1, 2 and 3
used
to
leg snap-fit
cable holder
as
used in
washing
machines and
Photo 1 shows
mability
means
of the
two
of slots. In the top half of the picture there are rollers with Hostaform bearings for dishwashers.
In the left
a clip with a similar function. Here snap-fit is secured by driving a pin into the hollow shank (expanding rivet). The clips for fixing car exterior trim (no. 6) work on the same principle. No. 7 shows the hinge fixing for a detergent dispenser tray flap on a washing machine.
dishwashers. No. 5 is
the
during assembly. With a barbed leg length 2.5 mm, the a barbed leg height of h maximum elongation at the vulnerable cross-section of the leg support point is:
=
0.75
=
mm
of 1
mm
=1
The lower half of the
f-h
=
0.058
5.f
picture
shows how
Hostaform
bearing end by a
flange.
Rotation of the
axially at one leg and at the other by a flange. bush is prevented by flattening off the
In all the
i
=
45
examples shown, the assembly angle the retaining angle 2 90 and the joints
=
are
non-detachable.
Photo 1
Photo 2
21
In
photo 3 another application from the automotive industry is shown. This is a Hostaform plug box which snap-fits into the fascia panel. The part is made in two symmetrical halves which are inserted into each other.
Photo 4 shows
a
non-cylindrical housing parts can legs. This air filter intake is made from Hostacom G2 N01 In assembling the two halves, the barbed legs are not deflected but the mount ing holes are elastically deformed.
joined by
barbed
.
a car
boot
lid, which
is secured
by
two
pairs
of barbed
legs.
Photo 3
Photo 5
22
8.2
Cylindrical snap-fit
a
Photo 7 shows
design
pneumatic positioning device for con trolling the flaps in air conditioning systems. The two Hostaform halves are snap-fitted together, thereby at the same time forming a seal by means of an O-ring. The operating pressure is 0.2 to 0.8 bar. The undercut depth is H 86.5 84 2.5 mm. Owing to the different wall thickness of the shaft and hub, the hub is extended more than the shaft during assembly. The diameter difference is apportioned between 1.56 mm expansion of the hub and 0.94 mm compression of the shaft.
= =
to
the
car,
which is similar in
It is controlled
a
Photo 6 shows
carburettor
secured The
vacuum.
Here,
too,
rubber
by the diaphragm is
two
by
the
the
halves.
assembly diameter is DG 60.8 mm and the under 1.6 mm. Assuming that during assembly cut depth H only the hub is expanded, the maximum permissible elongation is
=
1.6
e
=
100%
2.6%.
The
is i
45
and the
retaining
Photo 6
Photo 7
23
8.3
snap-fit
9.
=
Explanation of symbols
Unit
Photo 8 shows parts of a carburettor linkage made from Hostaform. The ball, with a diameter of DG 7.8 mm,
bears in
socket with
diameter of 7.85
mm.
The
special
not
Symbol
A
a
Explanation
area
design is the socket opening which is elliptical. The major axis of the ellipse
to
=
mm
corresponds
meter
the ball diameter DG 7.8 mm, the in length. In this direction, the dia mm
mm
deformation socket
and
difference is
H
b
7.8
-
mm
barb width
supported
=
7.5
mm
0.3
mm
Da
mm
Assuming
spread evenly around the circumference, during assembly the parts will be expanded by
0.3
e
=
Dr
mm
mm
(ball
and socket
snap-fit)
100 2-7.5
=
2%.
DK
mm
(cylindrical snap-fit)
mm
socket diameter
(ball
and socket
snap-fit)
Es
F, F2
h
H
J~Mnax.
N/mm2 N N
mm
secant
modulus force
(fig. 17)
assembly pull-out
barbed
force
mm
undercut
mm
maximum
permissible
undercut
Photo 8
mnr
depth
moment
of inertia
(table 3)
geometry factor
mm
(fig. 26)
edge
leg
and inside
edge
of hole
mm
barbed
leg length
mm
N/mm2
joint pressure p
^=
Es
J_
K
mm
o
wall thickness
% %
%/min
of
elongation
coefficient of friction
N/mm2
N/mm2 N/mm2
tensile
strength (table 4)
strength (table 4)
strength
24
10. Literature
Engineering plastics Design Calculations Applications [1]
[2]
H. Schmidt:
K.
Kunststoff, Verbindungstechnik,
Nos. 6, 7
[3]
design
concepts.
1977
International, August
Engineering plastics A. 1.1 Grades and properties A. 1.2 Grades and properties A. 1.4 Grades and properties A. 1.5 Grades and properties Vandar, Impet
A.2.1 Calculation A.2.2
Celanex,
principles
-
Hostaform
calculation
examples
-
A.2.3
Hostacom
calculation
examples
B.
Design of technical mouldings B.I.I Spur gears with gearwheels made from Hostaform, Celanex and Hostalen GUR
B.2.2 Worm gears with
worm
Hostaform
B.3.1
Design calculations for snap-fit joints in plastic parts Fastening with metal screws Plastic parts with integrally moulded threads Design calculations for press-fit joints Integral hinges in engineering plastics Ultrasonic welding and assembly of engineering plastics
C.2.2
C.3.1 C.3.3
C.3.4
C.3.5
of technical mouldings Indirectly heated, system conductive torpedo thermally Hot runner system Indirectly heated, thermally conductive torpedo Design principles and examples of moulds for processing Hostaform Machining Hostaform Design of mouldings made from engineering plastics Guidelines for the design of mouldings in engineering plastics Outsert moulding with Hostaform
runner
-
25
World-Class Engineering Polymers Celanex thermoplastic polyester (PBT) Celcon and Hostaform acetal copolymer (POM) Celstran and Compel long ber reinforced thermoplastics (LFRT) Fortron polyphenylene sulde (PPS) GUR ultra-high molecular weight polyethylene (UHMW-PE) Impet thermoplastic polyester (PET) Riteex thermoplastic polyester elastomer (TPC-ET) Vandar thermoplastic polyester alloy (PBT) Vectra liquid crystal polymer (LCP)
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