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This novel work investigates the internal turning of aluminium alloy using three cutting environments, i.e. dry, flood, and minimum quantity lubrication. The effect of variable machining parameters and cooling media drives the surface quality and tool effectiveness. The in-house fabricated experimental setup was used for the machining trials. A specially designed mist nozzle produces an aerosol used for sustainable machining. Shiny chips and improved surface finish are achieved during near-dry machining, even at higher feeds. The presented method's usefulness is attributed to high levels of association among conceptual, empirical, and literature survey results. The mist produced by supplying aerosol internally through a boring bar proved an effective technique for better surface integrity than conventional and flood lubrication.