Optimal Design of an Ultrasonic Transducer in Rotary Ultrasonic Machining

In this paper, an ultrasonic transducer is designed and optimized in order to reduce the error of resonance frequency and maximize the amplitude of the radiating tip. In order to get the basic dimensions of an ultrasonic transducer easily, resonance frequency equations are derived by using the traditional analytic method. Using ANSYS FEM software, we analyzed the vibration model of the transducer, including Modal Analysis and Harmonic Response Analysis. Studied how the length of two resonance rods affects the resonance frequency. By optimizing the dimensions of the ultrasonic transducer, the error of resonance frequency is reduced to 0.03%; the amplitude of the vibrating tip is up to 6.20 mu m. The optimal results show that the transducer designed in this paper has superior performance parameters and meets the requirements of machining.