This study focuses on optimizing face milling parameters for AA6061 aluminum alloy in high-speed machining to achieve optimal surface roughness, material removal rate, power consumption, and tool wear. Due to its properties, high-speed machining is crucial for productivity and surface finish in industries utilizing AA6061. Using a central composite design with a quadratic model, 21 randomized runs explored the effects of cutting speed (CS), feed rate (FR), depth of cut (DOC), and tool diameter (TD) on machining performance. The results identified optimal parameter settings, with a trial run at 7000 RPM cutting speed, 750 mm/min feed rate, 0.2 mm depth of cut, and 2 mm tool diameter resulting in surface roughness of 2.355 μm, material removal rate of 289221 mm3/min, power consumption of 83767.6 W, and tool wear of 1277 μm. These findings enhance machining efficiency and quality in high-speed machining of AA6061 aluminum alloy. © 2025 Elsevier B.V., All rights reserved.