Nomex honeycomb core is a kind of typical difficult-to-cut materials because of the characteristics of anisotropy and weak-stiffness. Aimed at solving the problem of chip removal and serious crushing on the chip side during the processing of Nomex honeycomb core with traditional trepanning tool

a new method of ultrasonic slotting Nomex honeycomb core with semi-circle arc tool was proposed. A new semi-circular arc tool was designed

the kinematic law of the semi-circular arc tool with ultrasonic vibration was analyzed

and the transition mechanism of continuous cutting into intermittent cutting was explained theoretically in ultrasonic cutting. On these basis

ultrasonic slotting tests of Nomex honeycomb core were carried out

and the influences of the amplitude and feed rate on cutting force and cutting quality were studied. The test results showed that satisfied processing results could be obtained by the ultrasonic slotting of Nomex honeycomb core with semi-circle arc tool

and the introduction of ultrasonic could effectively reduce the cutting force and improve the surface quality. The ultrasonic slotting technology of semi-circular arc tool provided a new method for highquality cutting process of the edge contour of the honeycomb core.