<p>The metal processing industry faces significant environmental and energy consumption challenges, which are increasingly important in global sustainability initiatives. Traditional metal-cutting methods, which involve substantial quantities of cutting fluids and generate considerable waste and emissions, are now considered unsustainable. The sustainability assessment and environmental impacts of cooling-lubricating assisted machining of Ti-6Al-4V alloys have not been studied holistically. This research aims to develop a new empirical model for the comprehensive understanding of the energy consumption and carbon emissions associated with clean-cutting processes. To achieve this, a series of milling tests were conducted using different clean-cutting techniques, including green wet cutting (pouring), Minimum Quantity Lubrication (MQL), Cryogenic CO₂ cooling and hybrid CO₂ mixed with minimum quantity lubrication ( CO₂-MQL ). The CO₂-MQL technique stood out among the tested methods, showing a remarkable improvement in energy efficiency and carbon emissions reduction. Specifically, this method demonstrated up to 30% better energy efficiency than traditional methods. Additionally, it significantly reduced carbon emissions, supporting the premise that integrating CO₂ with minimal quantity lubrication could offer a dual benefit of enhanced cooling and lubrication while minimizing environmental impact. The success of the CO₂-MQL technique highlights the potential for scalable improvements in energy and emissions reductions across the metal processing industry, suggesting a viable pathway toward greener manufacturing practices. This study provides fundamental knowledge about the environmental impact of machining processes used in metal processes industry and reduce waste related pollution.</p>