A review of surface quality control technology for robotic abrasive belt grinding of aero-engine blades

Higher requirements are being imposed on blade surface quality due to the continuous improvement of thrust-to-weight ratio and endurance in advanced aero-engines. Robot abrasive belt grinding offers the advantages of excellent flexibility, convenient scheduling, strong adaptability, and low cost. It aligns well with the development trend of multi-specification and small-batch blade processing, serving as an effective method to enhance blade contour accuracy and surface integrity. Nonetheless, the surface quality and contour accuracy of robot belt grinding are significantly influenced by factors such as the robot's low repeated positioning accuracy, weak structural stiffness, and elastic deformation during belt grinding. Consequently, the design and development of an efficient, flexible, and high-precision robotic belt grinding system hold significant importance in improving machining accuracy and controlling blade surface quality. Currently, there is extensive research on robotic belt grinding of aviation blades. However, there is a lack of comprehensive analysis of these technologies. To address this issue, we conducted an extensive literature review and utilized an inductive classification research approach to assess and analyze multiple key technologies associated with the processing technology. The study reveals the utilization of optimization algorithms and AI intelligent algorithms in various key technologies. Application of these algorithms results in a 70% improvement in the calibration accuracy of the robot system and a 20.5% enhancement in processing efficiency after trajectory planning. Furthermore, the integration of multiple sensors and analysis algorithms enables the prediction error of belt wear to be below 10% and achieves a prediction accuracy higher than 85% for surface roughness and residual stress. This paper aims to provide a comprehensive summary of the technology development related to surface quality control in robot belt grinding for aerial blades. It offers a range of technical options for building an intelligent and high-precision robot belt grinding system and contributes to the further advancement of surface quality control in blade grinding. Lastly, the paper presents a future outlook on the development of related technologies.