Resin matrix aramid honeycomb is widely used in aerospace fields due to its lightweight and highstrength characteristics. Ultrasonic vibration cutting is a significant forming method and tool wear is an important research direction. Full-life processing experiments of 3000 m and 2000 m were respectively carried out for straight blade tools and disc tools in ultrasonic cutting in this work. The wear evaluation was conducted through element analysis and microscopic feature extraction of effective parameters including edge radius and unevenness. Microscopic element analysis of the cutting edge area indicated that the content of hard particles of the cutting edge decreased during the processing

while soft matrix phase increased. The microscopic morphology observation of cutting edge showed that the unevenness of the cutting edge of the tool decreased significantly while the edge radius continuously increased. The tool wear can be characterized as “flattening” and “blunting”. Through finite element simulation of micro-element ultrasonic processing of aramid paper honeycomb and cutting experiment

the law was found that the cutting force constant in “initial wear” and then increasing in “continuous wear”. Indicating that two geometric morphology evaluation indicators proposed were verified to play a leading role in the processing. After verification

three extracted indicators had a prediction error of less than 15% in singlefactor processing mileage and a parameter collaborative prediction error of less than 5%.