Design of Hollow Horn Based on Four-terminal Network Method

When designing the horn of the ultrasonic transducer for rotary machining, the traditional analytical method cannot consider the complex assembly cross-section of the horn, resulting in a large final simulation error and design error. At the same time, when the design diameter of the transducer is too large, the size of the back mass obtained by the traditional analytical method is too thin. This paper combines the four terminal network method and the finite element method, selects the sandwich piezoelectric transducer, takes the ER spring chuck commonly used in rotary machining as an example, derives the transmission matrix corresponding to the geometric cross-section shape, and then uses the four-terminal network method and the traditional analytical method to design two sets of stepped ultrasonic transducers with the design frequency of 22 kHz for analysis and comparison. Finally, through the analysis, it is verified that the ultrasonic transducer designed by the four-terminal network method has a performance closer to the theoretical design.