The role of cutting fluids in machining operations is crucial, impacting productivity, tool lifespan, and work quality. An experimental investigation was conducted on ball end milling of AISI 1040 steel using uncoated HSS tools under various coolant conditions and milling modes. The study encompassed four coolant conditions: dry, mist, 4% coolant concentration, and 8% coolant concentration, with constant cutting parameters. Machining performance was assessed based on tool wear and surface roughness. Results indicate a significant influence of coolant conditions on machining performance and surface quality. Mist coolant in down milling mode exhibited superior performance in terms of tool wear and average surface roughness (0.09 mm and 0.462 μm, respectively). Following closely was mist coolant in up milling mode, then 8% coolant concentration, and lastly 4% coolant concentration under up milling mode. This research sheds light on the importance of coolant selection and milling mode in optimizing machining outcomes.