Computer-aided design of acoustic horns for ultrasonic machining using finite-element analysis

Ultrasonic machining has myriad applications in industry, especially with recent trends of using harder and stronger materials. The cutting performance of a machine depends on the ability of the design of the acoustic horn to facilitate an increase in tool-tip vibration, allowing a significant amount of material to be removed. In this paper, a computer-aided design procedure for the horn profile and material, based on finite-element analysis, has been established. A new design profile is suggested, using parts with different geometries. An optimization procedure for the profile has been followed to obtain maximum magnification, for higher rates of material removal and safe working stresses for the horn material.