Abstract:To solve the problems such as long machining cycle, high cost and low precision in mass production existed in traditional machining of straight tooth gear, a method of designing high precision straight tooth surface gear cathode structure was present. Using the section lofting method,the tooth surface modeling points were reasonably planned; the corresponding cathode surface model was established based on the equilibrium clearance theory. The cathode channel was designed using the reflux mode to improve the work efficiency and the processing precision. Finally an integrated ECM clamping system was designed. Through the electrochemical machining experiment,the straight tooth face gear part with the surface roughness below 1.6 μm and the comprehensive accuracy of IT9 level are obtained, which verify the feasibility of the design method.