Design and Experimental Study of Catenary Linear Horn Based on Ultrasonic Machining

The amplifier rod, also known as a concentrator, is an important component in ultrasonic transducer devices. Its main functions are amplitude amplification and impedance matching, playing a crucial role in ultrasonic machining systems. This article conducts modal analysis and harmonic response analysis of the horn and the tool-added horn, using simulation software, gradually studying the dynamic performance of the catenary linear horn in ultrasonic machining. The optimized frequency of the amplitude rod is obtained, and the effect of the resulting vibration frequency in actual processing is verified through atomization effect tests. The results show that the resonance frequency obtained by finite element analysis has a small error with the actual test, only 0.789%, and magnification error of about 0.165%, which meet the design requirements. It provides reliable design basis and data foundation for the engineering application of the variable rod in ultrasonic machining.