The article presents the use of computer graphics methods and computational geometry for the analysis on changes of geometrical parameters for a mixed zone in resistance-heated samples. To perform the physical simulation series of resistance heating process, the Gleeble 3800 physical simulator, located in the Institute for Ferrous Metallurgy in Gliwice, was used. The paper presents a description of the test stand and the method for performing the experiment. The numerical model is based on the Fourier-Kirchoff differential equation for unsteady heat flow with an internal volumetric heat source. In the case of direct heating of the sample, geometrical parameters of the remelting zone change rapidly. The described methodology of using shape descriptors to characterise the studied zone during the process allows to parametrise the heat influence zones. The shape descriptors were used for the chosen for characteristic timing steps of the simulation, which allowed the authors to describe the changes of the studied parameters as a function of temperature. Additionally, to determine the impact of external factors, the remelting zone parameters were estimated for two types of grips holding the sample, so-called hot grips of a shorter contact area with the sample, and so-called cold grips. Based on the collected data, conclusions were drawn on the impact of the process parameters on the localisation and shape of the mushy zone.
The paper presents a multi-scale mathematical model dedicated to a comprehensive simulation of resistance heating combined with the melting and controlled cooling of steel samples. Experiments in order to verify the formulated numerical model were performed using a Gleeble 3800 thermo-mechanical simulator. The model for the macro scale was based upon the solution of Fourier-Kirchhoff equation as regards predicting the distribution of temperature fields within the volume of the sample. The macro scale solution is complemented by a functional model generating voluminal heat sources, resulting from the electric current flowing through the sample. The model for the micro-scale, concerning the grain growth simulation, is based upon the probabilistic Monte Carlo algorithm, and on the minimization of the system energy. The model takes into account the forming mushy zone, where grains degrade at the melting stage – it is a unique feature of the micro-solution. The solution domains are coupled by the interpolation of node temperatures of the finite element mesh (the macro model) onto the Monte Carlo cells (micro model). The paper is complemented with examples of resistance heating results and macro- and micro-structural tests, along with test computations concerning the estimation of the range of zones with diverse dynamics of grain growth.