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Here is being focused to develop a metal matrix composite based on AA 6061 matrix and SiC particulate reinforcement through stir casting method. The micro-structural characterization and evaluation using SEM, EDS and XRD analyses are being performed to understand the properties of the developed composite. Further, the influence of SiC reinforcement percentage on the mechanical properties of the AA 6061 composites is being determined. The next phase of work focuses on investigating the significance of various machining parameters on the surface roughness, cutting force and metal removal rate (MRR) in the end milling process of Al/SiC composites. Finally, optimization of the machining process through Response Surface Methodology (RSM) and Genetic Algorithm (GA) is being attempted to determine the optimum values of input parameters for a minimum surface roughness and cutting forces with maximum MRR. The optimal configuration of factors and its responses with desirability value are identified using RSM and GA for the conventional and CNC end milling operations respectively.