In this research, a built-in actuated ultrasonically assisted turning (UAT) system was developed. The structure design and turning parameters of the system were optimized to improve its efficiency. Finite element analysis and robust design are used in the system structure design to optimize the system structure. The primary purpose of this optimization is to achieve the best tooltip vibration displacement of the system. When the natural frequency mode of the system is 23.7 kHz, the best-simulated tool tip vibration displacement for computer-aided engineering is 4.16 μm; at an input voltage of 100 V, it is 3.91 µm, the error percentage is 6.39%, and the accuracy is very high. Afterward, we conducted an optimization study on the turning parameters of heat-treated die steel. The best turning force is 8.658 N, the turning temperature is 354.9°C, and the surface roughness is 0.394 μm. Compared with conventional turning, our UAT system can reduce the turning force by 92.32%, the turning temperature by 30.43%, the surface roughness by 42.89%, and the tool wear by 95.22%. The comparison results show that our UAT system can significantly improve the efficiency of post-hot die steel turning.
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