An analytical model is presented for the prediction of aerosol generation from the use of metal cutting fluids. The model examines the primary mechanisms of spin-off, splash, and diffusion to formulate the airborne particulate concentration and size distribution in quantitative terms of fluid properties, fluid application conditions, cutting process parameters, as well as machining time. Experiments were performed with the use of light scattering particle measurement to calibrate and verify the analytical models. The predictive models developed herein can serve as a basis for the control and minimization of the use of cutting fluids in the interest of environmental consciousness.