Due to its unique thin-walled grid structure,traditional aluminum honeycomb core processing method is frequently accompanied by deformation and burrs,which is a critical factor limiting the application of aluminum honeycomb materials.Ultrasonic vibration machining has great potential in reducing machining defects.The finite element model was established,cutting simulations were conducted,and aluminum honeycomb core cutting experiments were performed.The surface morphology of aluminum honeycomb cores was investigated under different amplitudes and spindle speeds.Simultaneously,the wear degree of circular blades under different amplitudes was contrasted.The results indicate that,compared with the universal cutting,the longitudinal torsional composite ultrasonic vibration assisted cutting can attain better surface topography and diminish the number of cutting defects more effectively;with the increase of ultrasonic amplitude,the number of cutting defects is declined,the tool wear degree is descended as well and the uniformity of the cutting surface becomes better;however,if the ultrasonic amplitude is too high,the cell wall will be separated;an increase in spindle speed can efficaciously improve the deformation and separation of cell walls.Meanwhile,an optimal spindle speed is in the range from 1 350 r/min to 2 700 r/min,which minimizes the number of cutting defects.