<p>WC-based cemented carbide coatings, fabricated via supersonic flame spraying, exhibit excellent density and high bonding strength with substrates, making them widely applicable as wear-resistant coatings in aero-engines. However, their high hardness and wear resistance often lead to crack formation during grinding, which compromises coating longevity. Ultrasonic vibration-assisted grinding (UVAG) has shown promising results in processing various materials with high hardness and brittleness, yet its impact on surface damage in cemented carbide coatings remains unclear. This study investigates the influence of single abrasive cutting thickness and grinding speed on the grinding-induced damage of WC-10Co-4Cr coatings. The results demonstrate that UVAG consistently reduces the single abrasive grinding forces compared to conventional grinding. Specifically, the normal grinding force decreases by 4.4% to 47.8%, and the tangential grinding force drops by 16.7% to 32.2%. The surface profile of UVAG-processed grooves is smoother, with shallower micro-grooves and a reduction in the number and magnitude of surface protrusions and depressions. The surface damage in UVAG is primarily characterized by minor fractures and cracks, indicating superior surface quality compared to conventional grinding. This study provides insights into the mechanisms underlying the improved surface integrity achieved through UVAG of cemented carbide coatings. The findings suggest that UVAG is a promising approach for reducing grinding-induced damage and enhancing the performance of WC-10Co-4Cr coatings in aerospace applications.</p>