Ultrasonic technology has been applied in many industrial processes such as ultrasonic machining, welding, cutting, sewing, homogenizing, etc. In an ultrasonic system, acoustic horn transmits the vibration energy of ultrasonic transducer to the application area and amplifies the oscillation amplitude. Depending on the application and industrial operating conditions, different horns with different geometries and magnifications are required to be designed. In the present study exponential horns with rectangular cross-section for application in ultrasonic assisted grinding process are designed and analyzed. An analytical approach is applied to model this type of horns. For evaluating the analytical model, some acoustic horns are designed using analytical method and then analyzed by the finite-element method (FEM) in ANSYS. Then, their design parameters such as resonance frequency and amplification factor are compared and verified. A very good agreement is obtained between the results of analytical modeling and those of FEM simulation. Furthermore, geometrical modification was introduced as a solution to coincide the vibration related parameters of the horn to the desired design values. Moreover, a horn-workpiece assembly for applying in ultrasonic assisted grinding was simulated.