Abstract <p>Aluminum alloys such as 6061 and 6013 are widely used in the aviation and automotive industries due to their lightness and excellent mechanical properties. This study identifies energy-efficient parameter windows for 6061 and 6013 gear milling. The most suitable processing parameters were determined through experimental studies using Minitab software, and efforts were made to increase energy efficiency. A 2^4–1 fractional factorial design-based optimization study was proposed in this paper. A regression function was obtained from the experimental design results using the ANOVA analysis. Then, the obtained regression function was used as an objective function for the mathematical model, and the factor levels were used as the constraints for the parameters (factors or decision variables). Finally, 680&#xa0;rpm, Z55 (No. 7) tool type, and a 2&#xa0;mm depth of cut were determined as the minimum net current values for the milling process of Al6013 in blank generation operations to produce gear shapes. Due to the limited number of studies in literature, this study aims to make a significant contribution to the reduction of net current for 6061 and 6013 alloys. The predicted value and the experimental value are very close to each other (1.12% gap value).</p> Graphical Abstract <p></p>