Rotary ultrasonic machine (RUSM) has a lot of applications in industries, with the recent uses of stronger and harder materials. Machining performance of RUSM depends on the design of the horn. A horn also known as a tool holder or concentrator is a waveguide focusing device, which has a decreasing area of the cross section from the upper to lower end. In RUSM, the high amplification factor of the horn is required to increase tooltip vibration for getting a high material removal rate. In this study, the design of the horn using an optimization procedure and finite element analysis (FEA) has been done. FEA-based MATLAB code has been developed for finding all the stress components, axial amplitude, and resonance frequency. Results are validated from the experimental data available in the literature, and it has been found that it is in good agreement with the literature. The amplifications of the horns with cubic and quadratic profiles 23.8% and 19%, respectively, are higher than the traditional horn with the same length and diameters of the ends. Stresses at different locations have been found within the allowable endurance limit. The effect of frequency on the stress distribution has also been studied and found that the variation of stresses over the domain of horn increases with an increase in frequency, but the value of stress is much lower at the resonance frequency.

旋转超声机（RUSM）在工业中有许多应用，最近使用了更坚硬的材料。RUSM的加工性能取决于焊头的设计。喇叭也被称为工具架或集中器是波导聚焦装置，其横截面的面积从上端到下端逐渐减小。在RUSM中，需要喇叭的高放大倍数来增加工具提示的振动，以达到较高的材料去除率。在这项研究中，使用优化程序和有限元分析（FEA）进行了号角的设计。已经开发了基于FEA的MATLAB代码，用于查找所有应力分量，轴向振幅和共振频率。结果得到了文献中的实验数据的验证，并且已经发现它与文献非常吻合。具有相同的三次方和二次方轮廓的号角的放大率分别比具有相同长度和端部直径的传统号角的放大率高。在允许的耐久性极限内发现了不同位置的应力。还研究了频率对应力分布的影响，发现随着频率的增加，喇叭形区域内的应力变化会增加，但在共振频率下应力的值要低得多。在允许的耐久性极限内发现了不同位置的应力。还研究了频率对应力分布的影响，发现随着频率的增加，喇叭形区域内的应力变化会增加，但在共振频率下应力的值要低得多。在允许的耐久性极限内发现了不同位置的应力。还研究了频率对应力分布的影响，发现随着频率的增加，喇叭形区域内的应力变化会增加，但在共振频率下应力的值要低得多。