Advances in Multi-Level Compensation Strategy and Process Collaborative Optimization for Robotic Belt Grinding

Robotic belt grinding is an effective and widely adopted finishing method for superalloys, offering notable advantages such as high material removal capability, low heat input, and reduced workpiece damage. In addition, robots can readily integrate multiple sensors—such as infrared radiation cameras, force sensors, and high-speed cameras—which facilitate real-time monitoring of the grinding process and thereby enhance grinding quality control. With the establishment and continuous advancement of large-scale artificial intelligence (AI) data models, new breakthroughs have emerged in the optimization of robotic grinding processes. Owing to its dexterous workspace and advantages in high flexibility and cost-effectiveness, robotic belt grinding has become a critical process for the precision forming of complex curved components such as aero-engine blades and blisks. However, factors such as the limited absolute accuracy of industrial robots, time-varying grinding contact states, and significant transient boundary effects make it difficult for the current constant-parameter open-loop machining mode to simultaneously meet the demands for high material removal efficiency and high surface integrity on complex profiles. This paper systematically reviews the technologies for precision control and process optimization of robotic belt grinding aimed at pointwise precise material removal. First, the structural composition of the robotic belt grinding system and the material removal mechanism are analyzed. Then, centered on the compensation concept, a hierarchical progressive technical framework is outlined, covering geometric calibration compensation, force/position hybrid online compensation, transient entry boundary compensation, and system-level comprehensive compensation of multi-source errors, with a comparison of the applicable scenarios and the effects on shape and property control at each level. Furthermore, under the support of effective compensation, the collaborative optimization methods of material removal modeling, multi-objective optimization of process parameters, force-constrained trajectory planning, and intelligent adaptive processes are elaborated. Finally, current technical bottlenecks are summarized, and future trends in next-generation adaptive grinding technology driven by digital twins and embodied intelligence are envisioned. This review aims to provide a systematic theoretical reference for the high-precision and intelligent upgrading of robotic precision grinding systems.