Multi-tip tooling design for ultrasonic impact grinding of CMCs

A tool for ultrasonic impact grinding apparatus driven to vibrate along a longitudinal axis at an applied operating frequency, the tool comprising:

• a tool body disposed on the longitudinal axis, the tool body comprising:
• a horn configured to amplify a vibration amplitude, the horn having an output base at a terminal end;
• a first tip extending from the output base, the first tip having a first length;
• and
• a second tip extending in parallel to the first tip from the output base, the second tip having a second length, the second length greater than the first length;
• wherein each of the first tip and the second tip has a shaping portion configured to define a shape of an aperture formed in the workpiece via ultrasonic impact grinding;
• wherein the first tip and the second tip have first and second extension portions, respectfully, disposed between the shaping portion and the output base, wherein the first and second extension portions have the same shape and differ in length;
• and
• wherein a mass of the first tip is substantially the same as the mass of the second tip to provide a substantially uniform mass distribution across the output base and with respect to the longitudinal axis.