Based on the analysis of generating mechanism and mathematical model for the cylindrical gears with curvilinear shape teeth, a new way of modeling such gears for manufacture was proposed to solve the long existing inconsistencies between three-dimensional modeling and actual processing and to ensure the correctness of follow-up analysis of finite elements and gear machining. Adopting the secondary development of UG and the approach of gear blank’s rolling feed and gear cutting tool’s rotary, the three-dimensional model of such gears was accordingly built and proved to achieve rapid prototyping manufacture. Then, with the analysis of the model’s strength and finite elements performed, it was confirmed that the contact strength of tooth surface of cylindrical gears with curvilinear shape teeth could be substantially improved, compared with that of spur gears, and that the maximal stress equivalent was only twenty-seven percent of spur gears’. Meanwhile, the requirements of high speed and heavy duty gear transmission could be satisfied. Therefore, this approach was a good example of the establishment on strength theory and the design of processing, and provided theoretical basis and guidelines for industrial applications of cylindrical gears with curvilinear shape teeth in today’s China.
