<p>As a high-quality composite material, aluminum honeycomb cores have significant application value in key fields such as aerospace. However, its difficult-to-process characteristic has also made its processing a popular research topic. Studies showed that ultrasonic vibration-assisted cutting demonstrated excellent superiority in reducing processing defects and improving material properties. Therefore, in this study, a longitudinal torsional composite ultrasonic vibration system (LT-UVS) was designed, aiming to achieve high-quality processing of aluminum honeycomb cores on ordinary machine tools. By adding a chute structure to the self-designed ultrasonic oscillator, the coupling of longitudinal vibration and torsional vibration was successfully achieved. The experiment carried out the longitudinal torsional composite ultrasonic vibration-assisted cutting (LT-UVC) and the conventional cutting (CC) on the aluminum honeycomb cores under different geometric shapes of tools and different feed rates. The research results showed that the reasonable selection of process parameters can effectively reduce the cutting force and the number of defects generated during the processing. Compared with the serrated tools (ST), using the disc tools (DT) for the LT-UVC at a lower feed rate can achieve better processing quality. Furthermore, the results of the finite element simulation have also effectively verified the above conclusion. The results of this study have laid a solid foundation for the development of ultrasonic processing technology and the optimization of the processing quality of aluminum honeycomb cores.</p>