Abstract: In the machining of ultrasonic gear honing, the design of the transformer composed of solid horn and gear is a key technique, and dynamic characteristics of transformer have a significant impact on the machining quality of gear. The gear is load of solid horn, on the one hand , which has a influence on the resonant frequency of transformer due to its large size and heavy weight, such an influence could not be ignored in the designing of transformer; on the other hand, the gear’s size is determine by its application requirement, that can not be changed arbitrarily, so the existing design methods of solid horn in other ultrasonic machining are not suitable for this kind of circumstance . Based on the Mindlin theory for thick plate, the gear is simplified as a thick plate, its diameter is equal to pitch circle diameter of the gear, then the coupling relationship of the gear with the horn at the connection surface as well as their own dynamical equations are utilized to establish dynamical model of composite system of the gear and horn. On this basis, the transformer is designed and its dynamic characteristics is analyzed. The conclusion provide theoretical rules for the solid horn design. Finite element analysis verify the feasibility and effectiveness of the theoretical model.

Key words: Gear honing, Solid horn, Transformer, Ultrasonic machining