The purpose of this research is to evaluate the effects of a novel minimum quantity lubrication (MQL) technique and nano-MQL (N-MQL) during the cutting of AZ91D alloy on the surface of the machined area. Two groups were taken for the study, i.e., control group and the experimental group. The number of samples is calculated using a sample calculator. 12 samples were taken for each group. In the control group, the machining operation is carried out on AZ91D with MQL. In the experimental group using the novel N-MQL technique. The effect of the novel N-MQ technique on surface roughness is studied. Statistical testing was performed using SPSS (Statistical Package for the Social Sciences), and sample size was determined by setting the alpha level at 0.05 and the G-power at 80%. The average roughness for group 1 was 0.166833 m, compared to 0.94 m for group 2. Group 1 is MQL with AZ91D machining, and group 2 with N-MQL cutting. It investigated how the innovative MQL approach worked and influenced surface roughness. T-test analysis shows that there is a significant difference between groups 1 and 2 (significant at p = 0.001, or p < 0.05) in their mean variance of roughness. Surface quality significantly improves with the N-MQL method in relation to MQL and paved the way for green machining.

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