The findings underscore substantial variations in surface roughness based on lubrication status. Under lubricated conditions, surface roughness consistently decreases with higher cutting speeds and feed rates, indicative of smoother surfaces attributed to reduced frictional forces and effective chip removal. Conversely, non-lubricated scenarios exhibit greater surface roughness variability, highlighting the critical role of lubrication in stabilizing machining outcomes. Microhardness analysis reveals distinct trends between lubricated and non-lubricated machining. Lubricated processes generally enhance material hardness through increased plastic deformation and refined surface characteristics. In contrast, non-lubricated conditions yield lower and less uniform microhardness values, suggesting challenges in maintaining material integrity during machining nanofluid lubrication. Additionally, roundness error assessment demonstrates superior dimensional accuracy and part roundness in lubricated settings, attributed to minimized deformation and enhanced machining precision. Conversely, non-lubricated conditions exhibit higher roundness errors, underscoring lubricants’ crucial role in achieving stringent dimensional tolerances. In conclusion, the study indicates that nanofluids improve the accuracy of predicting surface roughness,microhardness, and roundness error compared to dry conditions, demonstrating better consistency and quality in roller burnishing results. It shows that nanofluids contribute to more accurate prediction of surface roughness, microhardness, and roundness defects compared to dry conditions, and shows effectiveness in roller burnishing result quality and consistency in the exact same way.