Abstract
<title>Abstract</title> <p>To achieve high-efficiency machining and low-noise transmission, an integrated manufacturing methodology is proposed for pure-rolling contact logarithmic spiral bevel gears (PCLSBGs) that combines flank modification design with digital generating machining. Based on spatial conjugate surface theory, a parabolic transmission error (TE) function was embedded into the pinion flank modification model to ensure pure-rolling kinematic conditions during meshing. Subsequently, a digital generating machining strategy suitable for general-purpose five-axis CNC machines was developed, in which a standard YW-type tangential face mill remained fixed while rotating, and the gear blank followed a precomputed arc-shaped spatial motion trajectory, inversely derived from a modified flank geometry to generate a completely modified tooth flank through enveloping. Simulation results indicated that the machining deviation of the digitally generated flank was below 1.5 µm. Tooth contact path simulations indicated that contact points were concentrated near the middle of the tooth flank, mitigating the edge contact and stress concentration. Machining trials further confirmed that the YW mill provided a wide cutting band, thereby overcoming dense toolpaths issues associated with ball-end mills in spiral bevel gear machining.</p>