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DETC2005-84415
DETC2005-84415
ABSTRACT 1. INTRODUCTION
This paper describes an interactive web-based design tool, A current trend in the design and manufacture of products
developed by using a web-based server application, for the is to reduce cost, part count and assembly time. As part of
three most common snap-fit features that are the cantilever Design for Manufacturing and Assembly (DFMA), features that
hook, post & dome and bayonet & finger. Response surface can be molded directly into a part such as snap-fit can be a
equations that predict each snap-fit features performance were quick, simple and cost effective way of assembling plastic parts
applied in this web-based design tool. This web-based design [1]. When designed properly, parts with snap-fits can be
tool also applied constraint management (CM), which helps the assembled and disassembled numerous times without any
designers switch the input and output on the fly and prevent adverse effect on the assembly. Snap-fits are also the most
over-constraint. Two other constraint management modules environmentally friendly form of assembly because of their
were applied. The first one is sensitivity analysis module used ease of disassembly, making components of different materials
to determine the inputs dependency to a specified output also easier to recycle. Figure 1 shows three commonly used snap-fit
applied in the design tool. The second one is correction advisor topologies that are discussed in this paper.
module used to see how much each dependent inputs value Traditionally, the snap-fit design process has been
should change if one output changes to a new value. Two disorganized and anecdotal in nature, relying greatly on the
optimization modules, single-objective optimization and skill and the experience of the individual designer. The most
multiple-objective optimization, are applied to optimize the popular source of information is the design guides from resin
performance of snap-fit features. suppliers such as Honeywell Plastics [1], GE Plastics [2] and
Finally a real design case for cantilever hook was Bayer Polymer [3]. However the information disseminated by
conducted and the results were compared to experiment results. these guides is fragmentary and often of various degrees of
. approximation. For example, the Euler-Bernoulli beam theory
KEYWORDS applied in these design guides is based on small deformation,
Assembly, Fastening & joining, Snap-fit, Web-based, which is commonly violated in real-world designs. It will be of
Design Tool, Constraint Management.. great value if design information for snap-fit features becomes
available to the designers in an abstracted form (as opposed to
NOMENCLATURE application-specific data).
Snap-fit design can be extremely variable, with the same
Insertion force: The force applied to a snap-fit feature to feature driven by very different constraints. For example when
engage it. designing a cantilever hook, one user may want to minimize its
Locking ratio: The ratio of maximum retention force to overall dimensions for packaging concerns while another user
maximum insertion force of a snap-fit may want to minimize the stress and strain due to material
feature. considerations. To facilitate this approach to design, this web-
Retention force: The force applied to a snap-fit feature to based design tool allows the user to switch design inputs and
disassemble it. design outputs in the design process. It can be considered
variational since the design factors used to drive the design do
not need to be known beforehand.
Solver
fi ( x1, x2,L, xN ) = 0,
i = 1, 2,L , M (4)
Equalities
Design
Inequalities Sensitivity xl x xu , i = 1, 2,L , N (5)
Optimizer Analysis &
Selection Constraint Correction
Manager Advisor
xi 0, i = n + 1, n + 2,L , N (6)
(Slack Variables)
Where N=n+p and M=m+p.
Interactive Web Browsers
Figure 2: System Architecture of the Web-based Design Tool If M=N: Fully-determined system
SENSITIVITY ANALYSIS
In product design it is advantages to know how ones
product will function away from nominal conditions. By
studying this, tolerance that are critical to performance can be
SINGLE-OBJECTIVE OPTIMIZATION
Single-objective optimization is used to optimize a single
parameter of snap-fit features. First an objective parameter
should be selected, and the designer should decide if he wants Figure 11: Single-objective optimization results for cantilever
to minimization or maximization the value. In this example, the hook
designer wants to maximize retention force. After all
parameters are inputted or solved except retention angle (Figure MULTIPLE-OBJECTIVE OPTIMIZATION
10), the optimum retention force was found and the design tool In this case, two parameters of cantilever hook want to be
also calculated the corresponding value for retention angle optimized: minimize insertion force and maximize retention
(Figure 11). force. Some parameters were inputted identified by Input
status and some parameters were solved based previous
inputted parameters identified by Output status before the
optimization. Two free parameters were remained identified by
N/A status. The weighted values of objective functions need
to be selected based on designers decision on their importance
and make sure the sum of these weighted values is 1 (Figure
12).
After the optimization, the optimized values of objective
functions were shown. The free remained parameters were also
solved based these optimized values (Figure 13).
9. CONCLUSION
This paper describes an interactive web-based design tool
for three different snap-fit features: cantilever hook, post &
dome, and bayonet & finger. To overcome the disadvantages of
the current design guides such as poor modeling of high angle
retention, the second order response surface models generated
by the combination between DOE and FEA were applied in the
design tool. An initial comparison tests were conducted to
verify the accuracy of the design tool. This web-based design
tool can be used to predict typical performance properties of
snap-fit features such as insertion force, retention force,
insertion strain and locking ratio. Constrain management
modules include sensitivity analysis module and correction
advisor module were applied to prevent over-constraint and
transfer the status of design factors on the fly.
REFERENCES