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In order to solve this problem, a thermal\u2013mechanical coupling model was developed to optimize the grinding parameters for a cracked tooth preparation robot. The grinding force model, based on an empirical formula, was established and analyzed. Using this model, the grinding temperature field of the tooth surface under a moving heat source was also determined. The optimal feed speed and rotational speed of the bur were identified through analysis. After verifying the model's accuracy through experiments, the stress intensity factor at the crack tips for various preparation parameters was calculated using the established thermal\u2013mechanical coupling model, enabling the determination of a safe parameter range. Robot\u2010assisted tooth preparation experiments were conducted based on the optimized preparation parameters, which resulted in a 19.32% reduction in normal grinding force and a 56.26% reduction in surface grinding temperature, and consequently a reduction in pulpal thermal damage compared to conventional preparation parameters. Crack extension following tooth preparation was observed by Micro\u2010CT scanning, and the success rate of preventing crack extension was 73.33%, 93.33%, and 86.67% in xoz, yoz, and xoy sections.<\/jats:p>","DOI":"10.1002\/cnm.70070","type":"journal-article","created":{"date-parts":[[2025,7,7]],"date-time":"2025-07-07T23:13:47Z","timestamp":1751930027000},"update-policy":"https:\/\/doi.org\/10.1002\/crossmark_policy","source":"Crossref","is-referenced-by-count":0,"title":["Crack Extension Analysis and Parameter Optimization in Robot\u2010Assisted Cracked Tooth Preparation Process: Finite Element Analysis and Experiment"],"prefix":"10.1002","volume":"41","author":[{"ORCID":"https:\/\/orcid.org\/0000-0003-0491-9236","authenticated-orcid":false,"given":"Jingang","family":"Jiang","sequence":"first","affiliation":[{"name":"Key Laboratory of Advanced Manufacturing and Intelligent Technology, Ministry of Education Harbin University of Science and Technology  Harbin China"},{"name":"Robotics 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