Abstract: The thin-wall cutting angle is a typical feature in the milling process of honeycomb materials, and the material removal mechanisms vary significantly under different thin-wall cutting angle conditions. A calculation model for the thin-wall cutting angle during the milling of aluminum honeycomb cores is established based on an analytical method. Combined with numerical simulations, the influence of the thin-wall cutting angle on the stress characteristics, bending deformation, and machining morphology of the honeycomb wall is systematically analyzed. Variations in the thin-wall cutting angle significantly alter the stress patterns of the honeycomb walls, and the stress characteristics further determine the deformation response. To address tearing type machining damage, an optimization strategy for radial depth of cut is proposed, aiming to avoid cutting angle ranges prone to tearing. Comparative experiments demonstrate that the number of tears on the machined surface is reduced by approximately 53.8%, and the average tear length is decreased by about 71.1%.