Longitudinal ultrasonic vibration-assisted high-speed dry milling (LUVAHSDM) is performed to improve cutting performance and surface quality of Ti-6Al-4V (TC4). Multifaceted comparisons are presented in milling results of AlCrN, AlCrSiN, AlTiN and AlTiSiN-coated tools in terms of milling force, milling temperature, tool wear, 3D surface roughness and residual stress. The results show that maximum milling force in both the feed and longitudinal directions first decreased and then increased with

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... ncreasing Al element content as well as single edge and average flank wear. Therefore, the surface roughness of TC4 becomes more uniform when using AlTiN-coated tools, the residual stress is greatly reduced to 98.57 MPa. Combining milling force, milling temperature, tool wear, 3D surface roughness and residual stress data, it is found that AITiN-coated tools achieve both excellent cutting performance and surface quality. The excellent machining performance demonstrates the feasibility and effectiveness of applying LUVAHSDM methods.