Manufacturing of micro-parts has become more important and necessary in many engineering fields such as electronics, computers, micro-motors, and micro-surgical instruments. Metal forming processes have a potential to be used for manufacturing of micro-parts owing to their high precision and high mass production capacity. Frictional behavior of contacting surfaces is very complex in micro-metal forming processes and often poses several challenges to the development of micro-forming processes. Therefore, it is important to evaluate the coefficient of friction in micro-scale parts as it is often required during the design stage of the micro-forming process. Double cup extrusion test is widely used to evaluate the frictional behavior in bulk forming processes as it represents the working conditions of these processes. In this work, a micro-double cup extrusion system with capability of superimposing ultrasonic vibrations was designed and built. The device can be used to study the frictional behavior at micro-scale level. The double cup extrusion test was simulated using ABAQUS finite element package and the required parameters for the subsequent design stage such as forming force were obtained. A concept design in which ultrasonic vibrations are superimposed to the die during the test was then developed. The geometry and dimensions of all components of the assembly were obtained using modal analysis of the process such that the die oscillated in the longitudinal mode with a frequency equal to the resonant frequency of the ultrasonic generator. Finally, by examining the displacement of the punches in an experimental test, the dimensions of the dies and the effective length of the punches were modified. The experimental results showed 10% discrepancy between the predicted and experimental natural frequency of the assembly. The simulation results showed that with increasing friction, the tendency of the material to move towards the upper punch increases and the force on the upper punch increases. Furthermore, the friction between the punches and the specimen had no effect on the height of cups if the same friction factor were used for the upper and lower punches with specimen. Keywords: Microforming, Double cup extrusion test, Ultrasonic vibration, Lubricant, Friction.