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This paper investigates the surface roughness and temperatures generated during metal machining processes such as lathe and orthogonal turn-mill operations on the most commonly used domestic material AISI 304 stainless steel. Grey relational analysis (GRA) is a tool for multi-response optimization that can be used in conjunction with the Taguchi approach is used for multi-response optimization. Furthermore, a sensitivity analysis utilizing regression models is performed to cross-check the consistency of GRA optimality with modifications in machining parameter levels. Use of sensitivity analysis resulted in much-finer machining parameter combinations for superior responses in environmentally friendly (dry and aerosol-mist conditions) machining in both the processes. [ABSTRACT FROM AUTHOR]