Based on the theory of ultrasonic vibration design and ultrasonic vibration horn

a straight blade cutter for ultrasonic assisted cutting of weak stiffness material was designed. The influence of length

thickness parameters of the blade on the resonant frequency

amplitude magnification and longitudinal amplitude of the tool was analyzed. The effects of the tool width and transverse direction and the distribution of lateral amplitude along the tool axis direction were discussed. For the particular ultrasonic vibration system

the tool parameters with the best overall performance were determined. The cutting edge simulation tool with different shape parameters was developed and tested on the same ultrasonic vibration system. The conclusion of the simulation analysis was verified. The theoretical analysis was in accordance with the experimental results. According to the optimum parameters determined by the theoretical analysis

the straight blade cutter was developed and its vibration performance was tested. The conclusion of the study provided theoretical guidance for the development of straight blade cutter for ultrasonic assisted machining.