- IS09001 2015
Gear Finishing
High Precision Gear Grinding
Achieve Perfection with Gear Finishing Process
When it comes to gears, precision isn’t optional — it’s essential. At NTG, we specialise in high-precision gear grinding and finishing processes that deliver smooth, durable, and high-performing gears for demanding industries across the UK and beyond.
Whether you need new gears manufactured or existing gears finished to exact tolerances, our advanced gear grinding services ensure you get components that run quieter, last longer, and reduce costly downtime.
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What is Gear Grinding?
Gear grinding is a precision finishing process used to refine the geometry and surface quality of gears. Using specialised grinding wheels, our CNC-controlled machines remove minute amounts of material to achieve the highest levels of dimensional accuracy and surface finish.
This process is especially important for:
- Hardened gears that must withstand heavy loads and high speeds.
- Applications needing noise reduction and smooth performance.
- Systems where proper mating contact between gear teeth is critical to efficiency.
The result is gears with accurate tooth profiles, excellent surface integrity, and the reliability needed for critical industries.
The NTG Gear Finishing Processes
Different gears, materials, and applications require different finishing techniques. That’s why NTG offers the full spectrum of gear finishing processes.
Gear Grinding – Maximum Precision
Our CNC form grinding and bevel gear grinding techniques use advanced threaded grinding wheels and abrasives such as aluminium oxide and silicon carbide. The process produces gears with superior surface quality and high dimensional accuracy, ideal for spur gears, helical gears, and straight-toothed bevel gears.
Gear Honing – Fine-Tuned Performance
Gear honing is a finishing method that improves surface roughness and extends the fatigue life of gears. Using honing machines and fine abrasives, it reduces excessive wear and provides excellent noise reduction. It is widely used in automotive transmissions where a smooth surface is essential.
Gear Lapping – Perfect Contact
In gear lapping, a gear-shaped lapping tool polishes the gear flanks to achieve the desired surface finish. This ensures proper mating contact and eliminates micro-irregularities in generated gear teeth. The process is often used for high-speed gearboxes and worm wheels where precise alignment matters.
Gear Shaving – Pre-Hardening Accuracy
The gear shaving process uses shaving cutters and a gear shaving tool to correct tooth spacing, improve surface integrity, and prepare unhardened gears for heat treatment. It is a fast and effective way to ensure a gear’s basic geometry is correct before final hardening.
Gear Burnishing – Strength Without Removal
Gear burnishing uses two hardened rolling dies to plastically deform hardened teeth without removing material. The process improves surface quality, enhances mechanical properties, and creates a smooth surface. Burnished gears resist excessive wear and enjoy extended tool life.
Together, these finishing processes ensure NTG can meet the specific requirements of every client, from small spur gears to large industrial components.
Step-by-Step: How Gear Grinding Works
- Heat Treatment – Many gears are hardened before grinding to increase strength.
- Mounting – The gear is secured on a precision machine tool.
- Selection of Grinding Wheel – Depending on material and tolerance, NTG uses aluminium oxide or silicon carbide abrasives.
- Rough Grinding – Initial passes remove material quickly but accurately.
- Fine Grinding – Successive passes refine the gear tooth profile.
- Finishing – Final passes ensure a smooth surface, correct pressure angle, and long-lasting accuracy.
- Inspection – Finished gears are measured against hardened master gears to confirm tolerances.
This step-by-step approach guarantees high accuracy and reliable results.
Applications and Industries Served
Automotive and Motorsport
In cars, trucks, and racing vehicles, gears face extreme demands. NTG supplies spur gears, helical gears, and hardened gears that reduce noise and ensure very high RPM operation. Our processes extend gear life and provide the reliability that manufacturers and teams depend on.
Aerospace and Defence
Aircraft engines, helicopters, and defence systems rely on gears with exceptional surface integrity and high accuracy. NTG’s precision gear grinding ensures safety and reliability in mission-critical environments.
Energy and Power Generation
From turbines to pumps, gears in energy systems endure enormous stress. By improving fatigue life and resisting plastic deformation, NTG gears help reduce downtime and improve efficiency in power plants and renewable energy installations.
Industrial and Heavy Machinery
In construction, mining, and robotics, gears must deliver dependable performance under heavy load. Our finishing processes prevent excessive wear, ensure proper mating contact, and support continuous operation.
Case Study: Solving Gear Wear in Automotive Manufacturing
A leading UK automotive supplier approached NTG with a problem: their transmission gears were suffering from excessive wear and causing frequent failures. After inspection, NTG recommended a combination of gear honing and gear lapping to improve surface finish and ensure smooth rotation.
The results:
- 30% reduction in noise levels
- 40% increase in gear lifespan
- Significant reduction in warranty claims
By applying the correct finishing processes, NTG helped the client cut costs and deliver a more reliable product.
The Benefits of Choosing NTG
- High Accuracy & Dimensional Control – Achieve the tightest tolerances for mission-critical applications.
- Extended Gear Life – Reduce downtime and improve ROI with gears that last.
- Noise Reduction – Create quieter, smoother-running systems.
- Surface Integrity – Improved surface quality and desired surface finish for long-term reliability.
- Expertise Across Materials – Experience with cast iron, hardened steels, and specialised alloys.
- Trusted by Industry Leaders – Over 40 years of experience supporting leading UK and global manufacturers.
Why NTG?
- UK Manufacturing Heritage – Over four decades of excellence in gear manufacturing.
- Cutting-Edge CNC Technology – Modern facilities equipped with advanced machine tools.
- ISO-Certified Processes – Guaranteed quality and compliance.
- Custom Solutions – From spur gears to single helical spur gears, we can engineer exactly what you need.
- Technical Expertise – Our engineers understand both the basic geometry and the complex challenges of modern gear design.
Let’s Talk Precision
When performance matters, trust NTG for your precision gear needs.
- Proven results in demanding industries
- Reliable, UK-based manufacturing
- Custom-engineered solutions
Request a Free Consultation and find out how NTG can extend the life, accuracy, and reliability of your gears.
Frequently Asked Questions
It is the controlled use of a grinding wheel to achieve high accuracy, a fine surface finish, and reliable gear tooth geometry.
NTG achieves tolerances within microns, ensuring high dimensional accuracy and proper mating contact.
Finishing includes grinding, honing, lapping, shaving, and burnishing. Each method improves surface quality and ensures long-lasting performance.
This often results from poor finishing, tooth spacing errors, or excessive wear. Our processes eliminate these issues by producing smooth surfaces and correcting gear tooth, resulting in misalignments.
Not always. Gear grinding noises can be caused by clutch issues, but also by worn gears, misalignment, or improper finishing.
Sectors such as aerospace, automotive, defence, robotics, and energy rely on precision gear finishing to ensure safety and reliability.