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High hardness and exceptional machinability characterize the 6061 aluminum alloy. It is also a substance that welds nicely. It is extensively utilized in the railroad, shipbuilding, and aviation industries. This study used the face milling process on cryogenically treated aluminum 6061 alloys with normal and cryogenically treated PVD-AlTiN coated inserts. An orthogonal Taguchi L18 array was utilized to plan the experiment. Three cutting speeds, three different feed rates, and two different cutting inserts with conventional and cryogenic treatment were the cutting parameters employed in the studies. Roughness measurements were made after each experiment. In addition, each experiment was repeated six times, and the wear of the cutting insert was measured. The optimization of wear and roughness parameters employed the Taguchi method. Additionally, wear and roughness variables were co-optimized using Gray Relational Analysis (GRA). Taguchi optimization settings were optimized for the smallest surface roughness; the standard insert had a cutting speed of 250 m/min and a feed rate of 0.15 mm/rev. Optimized wear parameters include non-cryogenically treated (untreated) inserts, 350 m/min cutting speed, and 0.30 mm/rev feed rate. In the optimization using GRA, the non-cryogenically treated insert, 450 m/min cutting speed, and 0.15 mm/rev feed rate are the standard optimum parameters for roughness and wear. In terms of little wear and roughness, non-cryogenically treated inserts fared best, according to Taguchi and GRA findings. [ABSTRACT FROM AUTHOR]