What is Converse?
Converse integrates process simulation with structural simulation. It can process different mesh topologies from both process and structural simulation models. In combination with MatScape, local microstructures and homogenized material properties are transferred to the macroscopic component level.
- Transfer of fiber orientations and weld lines into the FE model.
- Processing of pressures, temperatures, and geometric deviations such as shrinkage and warpage.
- Automated generation of solver-compatible FE model data without co-simulation.
Why traditional structural simulation often falls short when it comes to plastic components
Many FE models are based on idealized geometry and assumptions of homogeneous materials. Manufacturing-related factors such as fiber orientation, weld lines, stress distributions, or warpage are not taken into account - even though they significantly influence the actual behavior of the component.
Provide the virtual component for structural simulation
Converse converts the manufactured component and its relevant properties into a model that can be used for structural analysis. Local microstructures, such as fiber orientations and weld lines, are not only visualized but also specifically prepared for subsequent component analysis and evaluation.
- Element-by-element transfer of fiber orientations into the structural model
- Transfer of weld line positions into the structural model for strength asessment
- Transfer of deformations resulting from shrinkage and warpage into the structural model
- More realistic representation of anisotropic material behavior at the macroscopic component level
Robustly transferring process states to other structural models
In addition to microstructures, manufacturing-induced loads can also be incorporated into the structural analysis from the process simulation. This allows for the early evaluation of loads on tools and inserts.
- Transfer of melt pressures and temperatures to structural models
- Robust processing of different mesh topologies from process and structural simulation
- Evaluation of mapping quality prior to further use in the solver
Generate simulation-ready FE models for the downstream workflow
When used in conjunction with MatScape, Converse generates simulation-ready FE models that can be used directly in the respective FEA software. The subsequent simulation then runs independently of PART Software - quickly, transparently, and without the need for additional co-simulation.
- Automated generation of native FE model data
- Further simulations with your FEA software without external material models
- Open data handling for traceability, quality assurance, and data sharing
Interfaces and process variables
CRachFEM
Features
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Supported source/target combinations
Mixed meshes and assemblies Mixed meshes and assemblies can also be processed. The supported mesh topology may vary by interface. |
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Material Card Assignment Convenient assignment of material cards via the MatScape front end. Pre-calibrated and custom material cards Solver Syntax Only solver-native material cards are generated. No co-simulation is required (no external material models) - ensuring a simple, robust, and fast workflow. |
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Two-pane view Convenient side-by-side view of the source and target models for direct visual inspection. Overlay and linked view Overlay view and kinematically linked view for quick validation of the position and mapping results. Smart Positioning Automatic smart positioning for quick initial alignment of the source and target models. This is helpful when the source and target models are defined in different coordinate systems. Manual positioning Interactive manual positioning for special cases or targeted adjustments. |
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Search algorithm Support for a nearest-neighbor search algorithm as a robust foundation for data transmission. Search radius The search radius is customizable and can be adjusted to suit the geometry and mesh resolution. Deformation mapping Algorithm for automatically deforming the target model during deformation mapping, with export of the deformed model. Mapping Statistics Mapping statistics for quality control and for quickly assessing mapping quality. |
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Importing process variables (Source) and the FE structural model (Target) Process variables are imported directly from the injection molding simulation. The FE structural model is imported from the native solver input data. Export Transferred process variables are written directly into the FE input data file - optionally as an include file. Fiber orientations are exported along with anisotropic material cards. The generated files are immediately ready for simulation. Batch mode Control via batch mode for automated workflows |
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Supported source/target combinations and mixed assemblies
Supported source/target combinations
- 3D (solid) → 3D (solid)
- 3D (solid) → 2D (shell)
- 2D (shell) → 3D (solid)
- 2D (shell) → 2D (shell)
- 2.5D (surface) → 3D (solid)
- 2.5D (surface) → 2D (shell)
Mixed meshes and assemblies
Mixed meshes and assemblies can also be processed. The supported mesh topology may vary by interface.
Material Card Assignment and Use of the MatScape Scope
Material Card Assignment
Convenient assignment of material cards via the MatScape front end.
Pre-calibrated and custom material cards
Solver Syntax
Only solver-native material cards are generated. No co-simulation is required (no external material models) - ensuring a simple, robust, and fast workflow.
Visual inspection, position check, and manual adjustments
Two-pane view
Convenient side-by-side view of the source and target models for direct visual inspection.
Overlay and linked view
Overlay view and kinematically linked view for quick validation of the position and mapping results.
Smart Positioning
Automatic smart positioning for quick initial alignment of the source and target models. This is helpful when the source and target models are defined in different coordinate systems.
Manual positioning
Interactive manual positioning for special cases or targeted adjustments.
Algorithms, parameters, and transmission quality control
Search algorithm
Support for a nearest-neighbor search algorithm as a robust foundation for data transmission.
Search radius
The search radius is customizable and can be adjusted to suit the geometry and mesh resolution.
Deformation mapping
Algorithm for automatically deforming the target model during deformation mapping, with export of the deformed model.
Mapping Statistics
Mapping statistics for quality control and for quickly assessing mapping quality.
Reading process simulation data and writing FE model data
Importing process variables (Source) and the FE structural model (Target)
Process variables are imported directly from the injection molding simulation. The FE structural model is imported from the native solver input data.
Export
Transferred process variables are written directly into the FE input data file - optionally as an include file. Fiber orientations are exported along with anisotropic material cards. The generated files are immediately ready for simulation.
Batch mode
Control via batch mode for automated workflows
What our customers say
"Fresenius Medical Care's dialysis machines contain several plastic components that must withstand various mechanical stresses. For medical reasons, failure or malfunction is not an option. PART Engineering Software helps analyze the strength of the parts and increase confidence in the device."
“S-Life Plastics enables us to design our plastic components efficiently and in a standardized manner with regard to static and cyclic strength. This enhances the safety of our products and shortens their development times.”
"S-Life Plastics enables engineers to perform strength assessments based on material data, thereby achieving high simulation accuracy and enabling more reliable predictions of part lifespan."
"The operational load or regulatory requirement that must be met varies depending on the application. Safety considerations often involve short-term overloads, while quality considerations tend to focus on long-term or cyclic behavior. S-Life Plastics ultimately provides the answers to these questions."
Benefits
By integrating process simulation with structural simulation, Converse enables more accurate simulations by accounting for the component’s realistic mechanical behavior. The component’s manufacturability can also be verified in advance by taking into account manufacturing-induced loads.
Converse reduces
- Costs associated with running the simulation (CPU time, license fees), since only optimized FE model data is generated in the respective solver syntax
- Development time, since the use of native FE model data allows many variants to be simulated in a short time
- Parts and rework costs, since more accurate simulation results prevent over- or under-dimensioning and safeguard the manufacturing process
Converse increases
- Accuracy of the simulation results, as component properties - including those resulting from manufacturing processes - can be captured
- Reliability of simulation results, as FE model data is created based on professional, standardized procedures
- Confidence in the simulation results, as open data handling ensures that the applied procedures are traceable and verifiable