In order to simulate micromachining of Ti-Nb medical devices produced in situ by selective laser melting, it is necessary to use constitutive models that allow one to reproduce accurately the material behavior under extreme loading conditions. The identification of these models is often performed using experimental tension or compression data. In this work, compression tests are conducted to investigate the impact of the loading conditions and the laser-based powder bed fusion (LB-PBF) building directions on the mechanical behavior of $\beta$-Ti42Nb alloy. Compression tests are performed under two strain rates (1 s${}^{-1}$ and 10 s${}^{-1}$) and four temperatures (298 K, 673 K, 873 K and 1073 K). Two LB-PBF building directions are used for manufacturing the compression specimens. Therefore, different metallographic analyses (i.e., optical microscopy (OM), scanning electron microscopy (SEM), energy-dispersive X-ray (EDX), electron backscatter diffraction (EBSD) and X-ray diffraction) have been carried out on the deformed specimens to gain insight into the impact of the loading conditions on microstucture alterations. According to the results, whatever the loading conditions are, specimens manufactured with a building direction of 45${}^{\circ }$ exhibit higher flow stress than those produced with a building direction of 90${}^{\circ }$, highlighting the anisotropy of the as-LB-PBFed alloy. Additionally, the deformed alloy exhibits at room temperature a yielding strength of 1180 ± 40 MPa and a micro-hardness of 310 ± 7 HV${}_{0.1}$. Experimental observations demonstrated two strain localization modes: a highly deformed region corresponding to the localization of the plastic deformation in the central region of specimens and perpendicular to the compression direction and an adiabatic shear band oriented with an angle of ±45 with respect to same direction.

In this work, the effect of the crystallographic anisotropy on machining forces is studied through a thermomechanical approach based on rate sensitive plasticity based model. A crystal plasticity framework is adopted to formulate the required constitutive equations. The present approach takes into account the material thermoviscoplastic response, the shear strain rate distribution in the primary shear zone and their effects on the lattice rotation. The machining forces as well as the corresponding specific energies are calculated using two methods: (a) the total power minimization procedure and (b) the Merchant shear angle procedure. The proposed model is validated using cutting force data available in the literature. Then, it is used to gain insight into the effect of the crystallographic anisotropy on machining forces. According to the results, a strong dependence of the machining forces to the crystallographic orientations is obtained. The model is also used to analyze the of the cutting velocity on the shearing along crystallographic slip systems through the material thermomechanical response. In addition, it is observed that, compared to the total power minimization procedure, the Merchant shear angle procedure allows capturing the specific cutting energy trends due to the crystallographic anisotropy, in terms of peaks and valleys.

Ti-Nb alloys are high-profile candidates for the biomedical applications. However, because of poor surface integrity (i.e. residual stress and surface roughness), Ti-Nb implantable medical devices need to be machined in order to obtain functional surfaces finish. In this work, experimentaland numerical investigations are conducted to study the micro-cutting response of Ti42Nb titanium alloy produced by laser-based powder bed fusion. Experimental micro-cutting tests are carried out using precision turning lathe. Trials are performed with two cutting velocities of 60 m/min and 120 m/min and different feed rates, varying from 5 to 40μm/rev. For the numerical study, a porous crystal plasticity-based model is proposed to address the impact of anisotropy and microstructure heterogeneities of the polycrystalline material. The crystal plasticity-basedmodel is identified using strain–stress curves obtained from compression tests performed under two strain rates and a wide range of temperatures. Numerical micro-cutting simulations are performed in order to gain insight into the impact of microstructural features (i.e. crystallographic orientation and grain size) on the machinability of the alloy.According to the results, the effect of the strain rates and the temperature on the thermomechanical behavior of the Ti42Nb titanium alloy produced by laser-based powder bed fusion is correctly depicted. The model captured the strain localization on adiabatic shear band during compression tests. According to the micro-cutting simulations, the local variables such as temperature, damage and plastic deformation are strongly impacted by the crystallographic orientations and the grain size.In addition, depending on the crystallographic orientations, the chip morphology changes form continues, slightly segmented to largely segmented.