This paper investigates the tool/material interface boundary conditions in an actual operation environment. The aim is to establish a fundamental understanding of the tool/material interfacial mechanisms using finite element methods and to predict how the vibration parameters and material properties might influence the overall system performance. In the simulation, a 3D FE simulation is being developed using dynamic mechanical analysis to characterize the vibration parameters of the tool at its tuned frequency. A selection of the material and geometry required for the tool is examined in this analysis. An ultrasonic cutting system is then implemented to achieve maximize ultrasonic benefits. This knowledge is then used to maximize ultrasonic benefits, and to quantitatively identify a close approximate model of the interfacial boundary conditions for estimating the effects on the die termination in the analytical stages of design.