In order to obtain well work performance, a new design process and the optimal method are systemically presented during ultrasonic vibrator’s design. Firstly, the general dimensions are calculated according to formula of ultrasonic theory. Secondly, 3D model without flange is established, and the best position setting a flange has been conformed through finite element analysis (FEM). Then constraints are laid on the flange, and the best model of vibration is obtained based on model analysis. The results are benefit to the following control design of ultrasonic vibrator. Finally, an ultrasonic vibration system has been made, and a series of experiments validate the feasibility of the design method.