In order to obtain high-performance gear elements with integrated shape, using non-resonant theory, the gear grinding experiment and ultrasound-assisted grinding acoustic system were established. Firstly, a theoretical model founded on the non-resonant proposed methodology was constructed. The frequency equation and displacement characteristics of the vibration system were established based on the specified boundary conditions, and the geometric size of the ultrasonic amplitude with a design frequency of 20 kHz was established. The acoustic system was simulated employing finite element software, and the analysis revealed that its frequency range was 19648 Hz, which was consistent with the design outcome. Meanwhile, the amplitude of the end surface of the tool gear reaches 5.59 μm, and the vibration was stable. Secondly, according to the solution of geometric parameters, the acoustic performance test was carried out. The error between resonant frequency (20387 Hz) and design frequency was 1.93 %, and the amplitude was 4.5 μm, which met the requirements of ultrasonic assisted grinding gear. Finally, the grinding test was carried out. The study results show that compared to conventional gear grinding, ultrasonic supported grinding lessens the grinding force by 11.5 % to 35.4 % and, at most, lowers the grinding temperature by 22.5 %.