Abstract: Ultrasonic vibration can reduce honing forces efficiently, and ultrasonic cavitation and cutting fluids can play an important role in realizing real-time dynamical washing in order to decrease the blockage of honing wheel and increase the honing efficiency, so the gear honing combined with ultrasonic machining is a precision machining method of gears with good prospect of application. The gear with large diameter and small thickness, which is the object machined by ultrasonic honing, is a special load that influences the machining frequency of vibration system greatly, hence the horn and gear must be considered simultanecusly to establish the dynamic equations when the ultrasonic vibration system is designed. Therefore gear is simplified as a disc and is limited to vibrate transversely with nodal circles in the process of machining, and cone-shaped horn is adopted. The frequency equations of transformer that consists of the disc and horn are derived. Based on the equations, the amplifier is designed and its dynamic parameters are calculated numerically and analyzed by finite element method. The results are consistent with experimental measurement. Through calculating resonant frequencies of the horn and disc independently, the results show that the frequencies are not equal to one of transformer and the error is heavier, which means that the interaction between the horn and gear must be considered at same time when the transformer is designed, otherwise the large error will be caused.

Key words: Disc, Transformer, Transverse vibration, Ultrasonic machining, Fitting tolerance, Key words: Clamping temperature, Parameterized model, Shrink-fit tool holder