In ultrasonic machining (USM), higher amplitude is required for higher material removal rate (MRR). The objective of this research is to develop a new horn design for high displacement amplitude for getting maximum MRR within a working condition. The profile of the horn has been optimized and designed. Inthis analysis, optimization procedure and finite-element method have been used for the design of horn of USM. In this, the variation of stress components along the length of the horn has been studied. In the middle, maximum stress is found due to a change in cross-section but it is within the endurance limit of the horn material. The cubic Bezier horn as compared with traditional horn is up to 19% more amplified. Finally, an optimized cubic Bezier profile for the horn has been designed, which has maximum displacement amplitude for higher MRR andsafe working stresses for the horn material.