<p>Tungsten alloys have been widely used in military, aerospace, ‘and defense industries due to their excellent mechanical and physical properties. However, due to its typical difficult to machine characteristics, tungsten alloy processing faces enormous challenges. The application of ultrasonic elliptical vibration cutting (UEVC) technology has shown significant effects in improving the surface quality of finished products. However, the comparative effects of traditional cutting and UEVC on the surface integrity of tungsten alloys are still an area that requires further exploration. In addition, previous studies have not fully investigated the effect of ultrasonic power on the surface roughness and microhardness of the modified layer of tungsten alloy processed by UEVC. In view of this, this study adopted finite element simulation and experimental analysis methods to investigate the application of UEVC and traditional cutting methods in W93NiFe alloy. The study aims to identify the key differences between these two techniques in terms of surface morphology, microstructure, and microhardness. In addition, the study also delved into the relationship between ultrasound power and the surface morphology of tungsten alloys under UEVC. The research results indicate that compared with ordinary cutting methods, the surface scaling and arc pit cracking phenomena of workpieces machined by UEVC are reduced. In addition, the roughness of the processed surface and the depth of the metamorphic layer are significantly reduced. In addition, the roughness of the processed surface is significantly reduced, and the depth of the metamorphic layer decreases by about 50%. Meanwhile, the improvement of surface hardness and residual stress levels helps to enhance the accuracy and smoothness of processed materials. With the increase of ultrasonic energy level, the frequency of surface defects in tungsten alloy steadily increases, and the surface roughness also increases accordingly.</p>