Journal of Manufacturing Processes最新文献

{"title":"Surface topography control in CoCrMo alloy additive manufacturing through laser powder bed fusion process","authors":"Anup Kumar Maurya ,&nbsp;G. Sivakumar ,&nbsp;Murugaiyan Amirthalingam ,&nbsp;M. Kamaraj","doi":"10.1016/j.jmapro.2026.01.091","DOIUrl":"10.1016/j.jmapro.2026.01.091","url":null,"abstract":"<div><div>Laser powder bed fusion (LPBF) enables precise fabrication of CoCrMo alloy components for biomedical applications; however, achieving optimal surface properties for orthopedic implants remains challenging. Surface engineering plays a pivotal role in enhancing both biological and tribological responses, particularly in improving the adhesion of bioactive coatings. This study integrates LPBFed surface optimization with atmospheric plasma-sprayed (APS) hydroxyapatite (HAp) coatings to enhance interfacial bonding strength. LPBF process parameters were systematically optimized to tailor surface roughness, followed by APS deposition of HAp coatings on the optimized CoCrMo substrates. In this study, LPBF process parameters were varied to fabricate CoCrMo samples, and specimens were evaluated based on microhardness (320–375 ± 12 HV_0.5), porosity (&lt;1.1%), relative density (~98.9%), and surface roughness (R_a: 3–13 μm). Based on these criteria, three representative samples were selected for in-depth microstructural and mechanical characterization. Microstructural analysis revealed a dual-phase γ-FCC + ε-HCP (~14.4 vol%) matrix with cellular substructures, columnar grains, and oxide inclusions. Transmission electron microscopy (TEM) analysis revealed nano-sized chromium-rich oxides (~50 nm) and (Co, Mo, W)₂Si Laves phases along grain boundaries, which act as dislocation barriers and contribute to enhanced strength, strain hardening, and microstructural stability. The optimized LPBFed CoCrMo alloy exhibited a yield strength of ~800 ± 15 MPa and elongation of 8 ± 0.5%, attributed to the refined cellular structure, planar defects, and solid-solution strengthening. Following HAp deposition via APS, adhesion strength measurements revealed significantly enhanced interfacial bonding (~45 MPa) in a sample with optimized surface morphology. Scanning electron microscope observations confirmed reduced tensile cracking and improved coating cohesion. Nanoindentation further demonstrated superior hardness and elastic modulus, indicating dense and mechanically stable coatings. These results confirm that LPBF combined with parameter optimization and surface engineering can significantly improve the mechanical integrity and adhesion strength of bioactive coatings for advanced orthopedic implants.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"161 ","pages":"Pages 14-33"},"PeriodicalIF":6.8,"publicationDate":"2026-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146081616","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Resistance spot welding between aluminum and steel: A review of process mechanisms and advancement strategies for enhanced joint performance","authors":"Kang Zhou ,&nbsp;Baokai Ren ,&nbsp;Juntao Shen ,&nbsp;Ping Yao","doi":"10.1016/j.jmapro.2025.09.053","DOIUrl":"10.1016/j.jmapro.2025.09.053","url":null,"abstract":"<div><div>In this paper, recent advances in resistance spot welding (RSW) process between aluminum and steel are comprehensively reviewed. Aluminum and steel are important materials to achieve lightweight manufacturing in automobile and related industrial occasions. However, it is difficult to use conventional RSW process to join these two types of metal sheets, because the large difference in metallurgical properties between aluminum and steel can induce various welding defects, such as hard and brittle intermetallic compounds (IMCs), which significantly deteriorate welding quality during the process. The paper first considers research related to interfacial phenomena and bonding mechanisms, which focused on fundamental studies of the process such as temperature field and stress variation, double nugget evolution and IMC formation and distribution. Then the work on advances in various Al/steel RSW process optimization methods is comprehensively considered, which include using optimized electrode methods, adding auxiliary materials or using external energy field to assist the Al/steel RSW process and also introducing some hybrid optimization methods which combined other welding or joining processes. Some representative and remarkable works were presented in detail, and corresponding statistic and comparative information of different works using the same type of optimization methods were also provided. In addition, the comprehensive performances of the methods, which include some important criteria, are listed in detail. Although these works can provide optimization approaches to obtain Al/steel spot welded joint with satisfactory quality, the reliable implementation of these methods in high-volume industrial application requires further developments in process robustness and cost reduction. In these various improvement methods, the external energy field assisted method is a promising solution for practical applications because it does not require pre-treatment of the parent metal sheets and may allow convenient online adjustment and control. This paper also pays attention to the quality evaluation and process parameter optimization of the process, and provides a prediction about future trends in these aspects by combining advanced artificial intelligent methods based on a review and comprehensive analysis of some relative works. Furthermore, concluding remarks and suggestions for the future works are provided. This work is expected to provide references and insights for academic research and actual industrial application of Al/steel dissimilar metal RSW related areas.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"158 ","pages":"Pages 414-436"},"PeriodicalIF":6.8,"publicationDate":"2026-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146090387","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Process optimization of paper cup bottom-forming using FEM and experimental validation","authors":"Moaaz Safwa,&nbsp;Juho Bonifer,&nbsp;Hemantha Kumar Yeddu,&nbsp;Juha Varis,&nbsp;Ville Leminen","doi":"10.1016/j.jmapro.2026.01.095","DOIUrl":"10.1016/j.jmapro.2026.01.095","url":null,"abstract":"<div><div>The extensive use of single-use food and beverage containers continues to raise environmental concerns, particularly due to the limited recyclability of polyolefin-coated paperboards. While polyethylene-coated structures remain prevalent in current manufacturing practices, improving their formability is essential for both optimizing existing processes and enabling the future adoption of more sustainable barrier materials. This study focuses on the bottom-forming stage of paper cup production, a process critical to achieving structural integrity and sealing performance. A finite element modeling approach was employed to simulate deformation behavior and stress distribution during forming, with experimental trials conducted to validate key results. Process parameters such as curling depth and production speed were systematically varied to evaluate their influence on forming outcomes. The results demonstrate that a curling depth of 4.3 mm provides improved seal consistency and structural uniformity, particularly at lower production speeds (80 cups/min), thereby minimizing the risk of defects commonly observed in fast, high-volume manufacturing settings. These findings contribute to a better understanding of process-structure relationships in fiber-based composite forming and offer valuable insights for reducing material waste and enhancing process reliability in sustainable packaging manufacturing.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 581-590"},"PeriodicalIF":6.8,"publicationDate":"2026-01-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146080428","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Improving the weldability of press hardened steel to aluminum alloy in resistance spot welding using interlayer and ultrasonic assistance","authors":"Juntao Shen ,&nbsp;Baokai Ren ,&nbsp;Ping Yao ,&nbsp;Kang Zhou","doi":"10.1016/j.jmapro.2026.01.088","DOIUrl":"10.1016/j.jmapro.2026.01.088","url":null,"abstract":"<div><div>Vehicle light-weighting has driven growing interests in joining aluminum alloys with press hardened steel (PHS), a metal widely used for its high strength. However, the significant physical and chemical differences between aluminum and PHS lead to low welding compatibility in conventional resistance spot welding (RSW) process, and some typically hard and brittle Fe-Al intermetallic compounds (IMCs) forming during the process, which can significantly deteriorate joint performance. This work proposes an improved method for RSW process of AA6061 aluminum alloy and PHS by introducing a stainless steel interlayer (thickness: 0.25–0.5 mm) and ultrasonic longitudinal vibration. The effects of different interlayer thicknesses and process combinations: conventional RSW, with interlayer only, and with both of interlayer and ultrasonic assistance (UA) were investigated in terms of dynamic resistance, metallurgical characteristics, joint microstructure, and mechanical properties of the Al/PHS welded joint. Results show that the stainless steel interlayer could effectively prevent direct Al-PHS contact. Using 0.45 mm interlayer made the IMC thickness reduced from ∼50 μm without the interlayer to ∼2.3 μm. Ultrasonic vibration further reduced the IMC layer to ∼1.4 μm, and enhanced Fe diffusion toward the aluminum side. With a 0.45 mm thick interlayer, the joint obtained from UA-RSW process could achieve a peak load of 6.32kN, which was 65.6% higher than that of the process using the same thickness interlayer without UA. The fracture energy was increased from 4.393 J to 14.806 J, and the fracture mode of the joint changed from interfacial fracture to better button fracture. These findings demonstrate that the synergistic using of a stainless steel interlayer and ultrasonic vibration can enable effective joining of PHS and aluminum alloys, and offer a promising solution for joining dissimilar metals and ultra-high-strength steels in advanced lightweight structures.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 591-610"},"PeriodicalIF":6.8,"publicationDate":"2026-01-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146080331","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Structure, mechanical properties, and wear behavior of functionally graded hybrid AA6061-B4C-CNT composites using combined stir casting and centrifugal casting","authors":"Sukanta Sarkar ,&nbsp;Ujjal Dey ,&nbsp;Ketan Chouhan ,&nbsp;C.S. Kumar ,&nbsp;Siddhartha Roy","doi":"10.1016/j.jmapro.2026.01.094","DOIUrl":"10.1016/j.jmapro.2026.01.094","url":null,"abstract":"<div><div>A functionally graded hybrid Al-B₄C-CNT composite cylinder was fabricated using combined stir and centrifugal casting to improve the properties of both the outer and inner surfaces. While a dense B₄C-rich region of approx. 1 mm thickness was achieved at the outermost surface due to the higher density of B₄C particles over molten AA6061, the areas adjacent to the inner surface were preferentially reinforced by CNTs. Electron backscattered diffraction (EBSD) analysis confirmed grain refinement and increased local strain in reinforcement-rich regions, with the finest grains and highest kernel average misorientation (KAM) value observed in the region, preferentially enriched with the CNTs. Raman spectroscopy confirmed the gradient CNT distribution, and high-resolution transmission electron microscope analysis proved the strong interfacial bonding due to the formation of a thin Al₄C₃ layer. Due to the presence of high B₄C content, the highest hardness of 520 ± 30 HV was achieved at the outer periphery, while the presence of CNTs in the inner regions resulted in higher hardness in those regions compared to the reinforcement-free mid-thickness zone of the cylinder. Samples from five regions along the thickness — outer, outer-middle, middle, middle-inner, and inner were subjected to three-point bend and wear tests. The inner-middle part demonstrated the best combination of flexural strength and toughness (flexural strength ∼350 MPa and flexural strain ∼11%) along with the lowest coefficient of friction (= 0.23) and specific wear rate due to the uniformly distributed CNT reinforcement. In conventional centrifugal-cast functionally graded composites, the inner surface generally suffers from inferior properties due to the accumulation of defects. In that respect, this novel composite design with gradient distribution of hybrid reinforcements provides a methodology to reinforce both surfaces simultaneously.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"161 ","pages":"Pages 1-13"},"PeriodicalIF":6.8,"publicationDate":"2026-01-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146081615","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Influence of cryogenic temperature on machining mechanisms and surface integrity of CF/PEEK composites based thermo-mechanical coupling analysis","authors":"Zhaoxin Hou ,&nbsp;Shipeng Li ,&nbsp;Han Lv ,&nbsp;Hao Li ,&nbsp;Xuda Qin ,&nbsp;Qing Zhao ,&nbsp;Guoyu Fu ,&nbsp;Zhengwei Bao ,&nbsp;Zhitong Zhou","doi":"10.1016/j.jmapro.2026.01.093","DOIUrl":"10.1016/j.jmapro.2026.01.093","url":null,"abstract":"<div><div>To address the challenge of monitoring thermo-mechanical damage in CF/PEEK machining, this research establishes a pioneering high-fidelity microscale FE model. The model uniquely incorporates liquid nitrogen precooling and the heat-generation-transfer dynamics across the fiber, matrix, and interface, achieving accurate cutting temperature predictions (errors within 5% at ambient temperature and 12% under cryogenic conditions). The finding results demonstrate that liquid nitrogen cooling (−150 °C) reduces cutting temperatures by 56.4%–60.4%, effectively suppressing thermal damage effects while inducing matrix embrittlement. Under cryogenic conditions(−150 °C), chips across all four fiber orientations exhibit morphology tearing deterioration due to matrix brittleness. During ambient temperature (21 °C) machining, matrix flow forms protective overlayers that reduce fiber damage; conversely, cryogenic machining embrittles the matrix, weakening its rigid support capacity for fibers and exacerbating fiber fracture and interfacial debonding. Surface roughness parameters (Sa/Sz) increase by 31%–85% (0°-135° fiber orientations), with 135° specimens exhibiting the most severe degradation. This study elucidates the synergistic mechanism between temperature and fiber orientation on machining-induced damage in CF/PEEK composites, providing theoretical foundations for optimizing ambient temperature and cryogenic machining processes.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 624-641"},"PeriodicalIF":6.8,"publicationDate":"2026-01-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146080326","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"QA-VLM: Providing human-interpretable quality assessment for wire-feed laser additive manufacturing parts with vision language models","authors":"Qiaojie Zheng ,&nbsp;Jiucai Zhang ,&nbsp;Joy Gockel ,&nbsp;Michael B. Wakin ,&nbsp;Craig Brice ,&nbsp;Xiaoli Zhang","doi":"10.1016/j.jmapro.2026.01.071","DOIUrl":"10.1016/j.jmapro.2026.01.071","url":null,"abstract":"<div><div>Image-based quality assessment (QA) in additive manufacturing (AM) often relies heavily on the expertise and constant attention of skilled human operators. While machine learning and deep learning methods have been introduced to assist in this task, they typically provide black-box outputs without interpretable justifications, limiting their trust and adoption in real-world settings. In this work, we introduce a novel QA-VLM framework that leverages the attention mechanisms and reasoning capabilities of vision-language models (VLMs), enriched with application-specific knowledge distilled from peer-reviewed journal articles, to generate human-interpretable quality assessments. When evaluated on 24 single-bead samples produced by laser wire direct energy deposition (DED-LW), our framework demonstrates higher validity and consistency in explanation quality than off-the-shelf VLMs. These findings indicate that the literature-supported quality assessment model has the potential to improve reliability for QA tasks, motivating future validation on larger, multi-layer, and multi-pass builds, and broader process/material conditions.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 611-623"},"PeriodicalIF":6.8,"publicationDate":"2026-01-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146080329","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Enhancement of the wear resistance of NiCu alloy reinforced by graphene nanoplatelets and WC particles through circular oscillating laser directed energy deposition","authors":"Yining Hu ,&nbsp;Siyu Chen ,&nbsp;Guang Yang ,&nbsp;Lei Zhou ,&nbsp;Wanhui Zhao ,&nbsp;Tao Wang ,&nbsp;Yang Li","doi":"10.1016/j.jmapro.2026.01.092","DOIUrl":"10.1016/j.jmapro.2026.01.092","url":null,"abstract":"<div><div>This study aims to develop a NiCu-based composite with superior wear resistance and self-lubricating properties for critical tribological applications in aerospace and energy sectors. The NiCu, NiCu/graphene nanoplatelets (GNPs), NiCu/WC, and NiCu/GNPs/WC composites were fabricated on A3 steel substrates using circular oscillating laser-directed energy deposition (COL-DED) technology. The high-frequency laser beam oscillation effectively stirred the molten pool, refining grain structure and enhancing material properties. Microstructural analysis revealed that four materials consisted primarily of equiaxed grains with minor columnar grains. The grain sizes of the NiCu, NiCu/GNPs, NiCu/WC, and NiCu/GNPs/WC materials were 10.74 μm, 7.80 μm, 8.35 μm, and 7.12 μm, respectively, indicating that GNPs had a superior grain refinement effect compared to WC. The main phases of the NiCu/GNPs/WC composite were Ni-Cu, C, WC, and W₂C. Under the action of the laser, GNPs melted and formed amorphous graphite-Ni-Cu (G-Ni-Cu) hybrid spheres at the grain boundaries, while WC particles embedded in the NiCu matrix partially melted to form W₂C, WC, and other carbides. Compared to NiCu, the hardness of the NiCu/GNPs, NiCu/WC, and NiCu/GNPs/WC composites increased by approximately 11.36%, 6.70%, and 22.57%, respectively, while their wear mass loss was reduced by about 62.8%, 81.4%, and 85.4%, respectively. The NiCu/GNPs/WC composite exhibited the optimal wear resistance. The G-Ni-Cu graphite spheres reduced wear by pinning grain boundaries and forming a self-lubricating film at the wear interface, while WC particles provided support. Their synergistic effect significantly enhanced the wear performance of the NiCu alloy.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 571-580"},"PeriodicalIF":6.8,"publicationDate":"2026-01-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146080330","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Heterogeneous Al–Zn–Mg-Cu and Al–Cu–Li layered composite fabricated by friction deposition additive manufacturing","authors":"Shuwei Duan ,&nbsp;Yimeng Ye ,&nbsp;Yuyang Zou ,&nbsp;Tao Wang ,&nbsp;Xiaoyang Yi ,&nbsp;Zhongli Liu ,&nbsp;Kenji Matsuda ,&nbsp;Yong Zou ,&nbsp;Fuqiang Guo","doi":"10.1016/j.jmapro.2026.01.084","DOIUrl":"10.1016/j.jmapro.2026.01.084","url":null,"abstract":"<div><div>Solid-state additive manufacturing of high-strength aluminum composites offers a promising route to overcome performance trade-offs inherent in monolithic alloys. This study presents the fabrication of a layered Al–Cu–Li/Al–Zn–Mg–Cu composite via friction surfacing deposition additive manufacturing (FSD-AM). Microstructural and mechanical analyses reveal sound interfacial bonding achieved through materials plastic flow and transfer, without forming detectable intermetallic compounds or continuous diffusion layers. The Al–Zn–Mg–Cu layers exhibit a finer recrystallized grain structure and a high number density of η' (MgZn₂) precipitates, delivering a tensile strength exceeding 500 MPa. In contrast, the Al–Cu–Li layers, with coarser grains and sparse T₁ (Al₂CuLi) precipitates, provide superior ductility (&gt;18% elongation). This architecture, comprising alternating “high-strength/low-ductility” and “medium-strength/high-ductility” layers of dissimilar high-strength aluminum alloys, coupled with a balanced corrosion performance, demonstrates a possible strategy to synergistically tailor strength, ductility, and durability for next-generation aerospace structures.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 509-515"},"PeriodicalIF":6.8,"publicationDate":"2026-01-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146080327","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"The modelling and compensation method for dove-prism-based laser trepanning optomechanical system","authors":"Muyang Ye ,&nbsp;Haohua Xiu ,&nbsp;Chung Ket Thein ,&nbsp;Haotian Cui ,&nbsp;Yongjie Zhao ,&nbsp;Gongyu Liu ,&nbsp;Jing Wang ,&nbsp;Hao Nan Li","doi":"10.1016/j.jmapro.2026.01.017","DOIUrl":"10.1016/j.jmapro.2026.01.017","url":null,"abstract":"<div><div>Laser beam drilling is widely employed in the aerospace industry due to its non-contact nature and efficient processing of various materials. While traditional fixed laser beam drilling methods such as Single Pulse Drilling (SPD) and Percussion Laser Drilling (PLD) are commonly used, mobile laser beam drilling techniques like Laser Trepanning and Helical Drilling are preferred for applications requiring precise control over hole geometric accuracy. This paper presents a new Dove-prism-based trepanning system model that enables analytical calculation of the laser trajectory within a 3D spiral domain. This model facilitates accurate prediction of drilled hole geometries, including diameter and taper. An innovative aspect of this study lies in the incorporation of a laser ablation effect into the prediction of hole geometry, which is often overlooked in other trepanning drilling research. By integrating a prediction function for ablation crater diameter, the accuracy of hole geometry prediction can be improved. The validity of the model is confirmed through extensive experiments, establishing its reliability while revealing important insights such as the impact of initial optomechanical conditions on hole geometry and the influence of laser parameters on hole circularity. Additionally, our compensation method enhances predictability and expands achievable geometry range when drilling holes. This research establishes a robust theoretical foundation for advancing mobile laser drilling technology, particularly in terms of system design and process optimization.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 480-497"},"PeriodicalIF":6.8,"publicationDate":"2026-01-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146080392","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}