Mechanical micro-cutting is one of the advanced processes for manufacturing of micro-parts. During the micro-cutting process, the thickness of the uncut chip is very close to the tip radius of the tool. The cutting edge is used to cut and extrude the workpiece. In this paper, the experiments and simulations of macro-machining nickel alloy are compared, and the process of micro-cutting nickel alloy is simulated and analyzed. In this study, four cutting edge radii, three cutting speeds, six hot cutting temperatures, and a constant depth of cut are used. The radius of the cutting edge of different sizes is theoretically analyzed and verified by simulation of material flow state, temperature, stress, strain, and cutting force. The results show that the material separation points are very close together at different cutting edge radii. The change in the radius of the cutting edge changed the contact state of the material in the cutting area, which has a large influence on the temperature and cutting force. The effects of different cutting speeds and hot working temperature on the machining process are also discussed.
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