In this paper, a contribution to the determination of reliable cutting parameters is presented, which is minimizing the expected machining cost and maximizing the expected production rate, with taking into account the uncertainties of uncontrollable factors. The concept of failure probability of stochastic production limitations is integrated into constrained and unconstrained formulations of multi-objective optimization problems. New probabilistic version of the nondominated sorting genetic algorithm P-NSGA-II, which incorporates the Monte Carlo simulations for accurate assessment of cumulative distribution functions, was developed and applied in two numerical examples based on similar and anterior work. In the first case, it is a question of the search space that is completely 'closed' by high natural variability related to the multi-pass roughing operation: in this case, the failure risk of technological limitations are considered as objectives to minimize with economic objectives. The second case is related to deformed search space due to the uncertainties specific to finishing operation; therefore, the economic objectives are minimized under imposed maximum probabilities of failure. In both situations, the efficiency and robustness of optimal solutions generated by the P-NSGA-II algorithm are analysed, discussed and compared with sequence of unconstrained minimization technique (SUMT) method. Keywords Failure probability . Monte Carlo simulations . Pareto optimal solutions . Optimization . NSGA-II . Reliable machining parameters Nomenclature R max The maximum roughness (μm) T max The maximum tool life (min) F max The maximum cutting force (kg) P max Power on the spindle (kW) L Length to be machined for a single pass (mm) d Diameter of workpiece (mm) t m Cutting time (min) t l Nonproductive and handling time (min) t r Tool changing time (min/edge) a Depth of cut (mm) t Total depth of metal to be cut in roughing operation (mm) n Number of passes in rough machining (an integer) p 0Direct labour cost added to overhead (paise/min) p 0 *t m Machining cost by actual time in cut (paise/pc) p 0 *t l Machine idle cost due to loading and unloading operations (paise) p l *(t m /T) Tool cost per unit piece (paise/pc) p lThe cost of a cutting edge (paise/edge) p 0 *(t r *t m / T) Tool replacement cost (paise/pc) r ε Nominal nose radius (mm) ηNominal machine efficiency (%) EThe expectation measurement