The work aims to obtain longer tool life in ultrasonic longitudinal-torsional vibration milling. The tool wear characteristics were studied by theoretical modeling and different milling vibration modes. The surface topography of the tool and surface roughness of the workpiece were analyzed by the electron microscope (VHX-2000) and surface profiler. Titanium alloys materials were processed by different milling methods and the wear characteristics of tool were analyzed systematically. Compared with the ordinary and ultrasonic longitudinal vibration milling, the ultrasonic longitudinal-torsional vibration milling reduced the wear on the flank surface of tool and improved the roughness of workpiece surface. Through the test, when the removal area was 6356 mm2, the flank wear under the ultrasonic longitudinal-torsional vibration milling was 103 μm, respectively dropping by 38 μm and 36 μm than that under ordinary and longitudinal ultrasonic milling. When removal area was 4530 mm2, the roughness Ra was 1.2 μm and Ra for the ordinary and the longitudinal vibration were 1.62 μm and 1.38 μm respectively. Due to the axial separation of ultrasonic longitudinal vibration, the flank continuously impacted the processed surface. The ultrasonic longitudinal vibration method caused more flank wear than the ordinary when removal area reached 6256 mm2. Ultrasonic longitudinal-torsional vibration machining realizes the actual separation of tool and chip in rotation direction and greatly reduces the impact to the processed surface by flank, thus extending the tool life and providing a new machining method for high-efficient processing and difficult-to-machine-material.