Abstract: A flexible remanufacturing system based on arc welding robot was built, which consisted of three subsystems:measuring subsystem, modeling subsystem and off-line programming subsystem. The coordinates of the worn workpiece is acquired by the measuring subsystem; remanufacturing model is built by the modeling subsystem; remanufacturing program is generated by the off-line programming subsystem, and then the remanufacturing process is achieved by the robot.The structure of the remanufacturing system and the principle of the three subsystems were described. The system can be easily employed in automatic remanufacturing of workpiece of quadric surface, with various state of surface damage. Remanufacturing test on a torsion bar shows that the system is feasible.