Patent ID: 8212171

Claim:
A system for ultrasonic assisted electrical discharge machining of a component part having a longitudinal axis, a half wavelength resonant frequency along the longitudinal axis and an attachment portion, the system comprising: an ultrasonic horn having a longitudinal axis, a half wavelength resonant frequency along the longitudinal axis and an attachment portion; wherein the half wavelength resonant frequency of the ultrasonic horn is provided to match the half wavelength resonant frequency of the component part; wherein one of the attachment portion of the component part and the attachment portion of the ultrasonic horn comprises a male part and the other one of the attachment portion of the component part and the attachment portion of the ultrasonic horn comprises a female part sized and shaped to mate and engage one another when the component part and the ultrasonic horn are at generally the same temperature; wherein the female part is formed of a material having a greater coefficient of thermal expansion than does the male part; wherein the attachment portion of the ultrasonic horn comprises a female part and is adapted to receive a male part of the component part; and wherein the ultrasonic horn is formed from one of titanium and aluminum and is adapted to receive a component part formed from steel.