“全工序法”加工弧齿锥齿轮相比传统的“五刀法”有生产效率高、成本低、加工精度高、齿轮强度高等优点。由于“全工序法”用一把刀盘同时切削凹面和凸面，所以接触区的调整比“五刀法”要困难许多。本项目对基于Free-form式机床的“定摆角”全工序法的主动设计制造理论开展研究，充分利用Free-form式机床的灵活性和自由度，设计制造出啮合性能良好的齿面。首先，建立全工序法弧齿锥齿轮的齿面主动设计理论，包括齿坯宏观参数修正和齿面微观形式的主动设计；其次，建立直接面向Free-form式机床的“定摆角”全工序法制造理论，从理论上保证加工出设计齿面的同时也加工出设计齿深，且不需要工件摆动轴参与联动；然后，建立针对实际工况的全工序法齿面修形设计方法；最后，揭示全工序法点接触齿面的啮合行为规律，揭示加工参数误差对齿面的影响规律。以期提高全工序法齿轮的啮合性能，为提升弧齿锥齿轮设计制造水平提供理论和技术支持。

Compared with the traditional “five-cut method”, “the completing process method” has significant advantages such as efficiency increase, cost reduction, machining accuracy improvement, tooth strength enhancement, and so on. Since the concave and convex flank are cut simultaneously by one cutter, the contact pattern adjustment by “the completing process method” is much more difficult than that by “the five-cut method”. This study conducts a research on the active design and manufacture of spiral bevel gear by the completing process method with fixed workpiece axis based on the Free-form type machine tool, and takes full advantage of the flexibility and freedom of the Free-form type machine tool, which is beneficial to the design and manufacture of high-performance tooth surface. First, the active design theory of tooth surface by the completing process method is established, including gear macrogeometry modification and active design of tooth surface microgeometry. Second, the completing process manufacture theory with fixed workpiece axis based on the Free-form type machine tool is established, with which the designed tooth surface and tooth depth are guaranteed theoretically, and the workpiece axis can stay fixed. Third, the tooth surface modification method aiming at the actual working conditions is established. Finally, the meshing performance rule of the point contact tooth surface by the completing process method is revealed, and the influence rule of the machining parameter error on the tooth surface topology is revealed. The primary target of this study is to improve the meshing performance of spiral bevel gear by the completing process method, and to provide technical and theoretical support for the promotion of design and manufacture level of spiral bevel gear.