Theoretical and experimental methods have been established for measuring mechanical load impedance at the tool tip surface in ultrasonic machining. Expression formulas of the mechanical load impedance were derived from the electrical equivalent circuit of the mechanical vibrating system, consisting of a magnetostriction transducer, a metallic horn and a tool. Mechanical load impedance was calculated by the previous formulas in measuring the free impedance of the transducer with no load and with load. The free impedance of the transducer at high power level was obtained by measuring the terminal voltage, current and electric power by a special high frequency wattmeter. The magnetostriction transducer was made of nickel, and the natural frequency was 20. 2 kc/s. Two types of exponential horns, (rectangular and circular section), two tools (rectangular thin plate and circular rod) and two kinds of abrasives (green carborandum of 200 and 1000 mesh) were used fir the experiments. It was found out that the mechanical load impedance consists of mechanical resistance and stiffness reactance, and that it takes different values by the shape and vibration amplitude of the tool tip, even when the other conditions (static contact pressure, machined depth and kinds of abrasive, etc. ) were the same. When static contact pressure and vibration amplitude of the tool tip were increased, the mechanical resistance and stiffness were also increased, but the variation of the resonance frequency of the mechanical vibration system were only 1〜2%. In the case of the tool of circular section, mechanical resistance and stiffness were 3x10^2 dyne/kine/mm^2 and 3x10^7 dyne/cm/mm^2 respectively at 250 gr/mm^2 for steatite and 3x10^3 dyne/kine/mm^2 and 5x10^7 dyne/cm/mm^2 respectively at 400 gr/mm^2 for super hardness alloy. The effects of grain size of the abrasive on the value of the mechanical load impedance were found to be very sligit.
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