<p>This study explores how tool geometry impacts secondary micro-cutting behavior of the FeCoCrNiAl_0.6high-entropy alloy through finite element analysis. The investigation focuses on the influence of rake angle, clearance angle, and tool tip radius on cutting force, thermal characteristics, and residual stress distribution. Simulation results indicate that, during the second cutting pass, both cutting force and temperature increase significantly compared to the first pass. A larger rake angle contributes to a reduction in cutting force along the X-axis, whereas an increased clearance angle results in higher cutting forces. Additionally, elevated rake angles are associated with lower cutting temperatures, while both an increased clearance angle and a larger tool tip radius tend to raise thermal levels at the cutting zone. In terms of residual stress, compressive stress diminishes with higher cutting speed but intensifies as cutting depth increases. Notably, the second pass generates substantially greater residual stress, with peak tensile stress exceeding that of the first pass by approximately 151.86&#xa0;MPa. These findings underscore the critical role of tool geometry optimization in mitigating thermal accumulation and controlling residual stress in precision micro-cutting applications.</p>