The goal of this research was to characterize the mist formation process. The salient machining and metalworking fluid parameters affecting the mist generation rate and size distribution of each mist formation mechanism were identified. Empirical equations predicting the mist generation rate or size distribution were developed. Results showed that impaction generated the least amount of mist. The generation was determined by fluid flow, and the mass median diameter and, the size distribution were influenced by fluid viscosity. On the other hand, centrifugal force most important formation mechanism and generated the largest drops. The mist generation rate depended on the amount of heat produced during machining and the heat absorption capacity of the metalworking fluid. Cut depth and rotational speed determined the amount of heat generated; whereas the type of metalworking fluid and fluid flow specified the heat absorption capacity. These parameters were combined into a dimensionless mist generation number that predicted the mist generation rate.
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