Create Doubler Design Enablers

Doublers are design enablers that provide localized performance benefits for multiple design attributes such as NVH, Safety, and so on. When their position and thickness are precisely designed, doublers can reduce mass and increase performance as they eliminate up-gauging of entire part(s). Typically, doublers are typically welded on one side and bonded with structural adhesive on the other side and can be incorporated even during the late stages of the product design cycle.

Figure 1. Automotive body in white with a doubler

1. From the Mesh ribbon, click the arrow next to the 2D Mesh tool set name and select Doubler from the list of options.
2. With the Element selector active on the guide bar, select the elements where the doubler needs to be roughly located.

   
   
   Figure 2.

3. Click Base on the guide bar then select the base node.
   Note: The base node must be on the longest face of the selected elements. Figure 3 shows correct “Base” node selection. Figure 4 shows incorrect “Base” node selection that will not create a bulkhead.

   
   
   Figure 3. Correct "Base" node selection (from the longest face)

   
   
   Figure 4. Incorrect "Base" node selection

4. Use the microdialog to edit the thickness of the doubler, the flange width, the length, and the mesh size.
5. Optional: Use the other icons in the microdialog to further define the doubler.
   • - modify the direction and orientation
   • - select a material
   • - select predefined connection control
   • - select edges to differentiate flanges from doubler face (see Doubler Edge Selection)

     
     
     Figure 5. Edge selection

6. Click on the guide bar.
   The doubler is created within a new component. The appropriate property card image (for example, PSHELL for the OptiStruct solver profile) is also created.

   
   
   Figure 6. Doubler preview

   
   
   Figure 7. Doubler parameters with material and connection control selection

   
   
   Figure 8. Doubler with connectors