Aluminum honeycomb structures are widely used in aerospace due to their excellent stiffness-to-weight ratio. However, their thin-walled architecture makes them difficult to machine, leading to deformation, material buildup, tool wear, and surface degradation. This study analyzes ultrasonic vibration-assisted milling of aluminum honeycomb structures by combining 3D numerical modeling and experimental validation. A finite element model using Abaqus/Explicit, based on the Johnson–Cook law, is devel