Cutting fluid mist is becoming an increasing concern for manufacturers as additional information is obtained on the health risks that it poses. While mist can be minimized through collectors or chemical mist suppressant additives, these approaches are expensive and often ineffective. This paper describes recent experimental efforts to study the mist formation problem in a turning process. Models that have been developed to describe the mechanics of mist formation are presented. Fluid vaporization under ambient temperature conditions is shown to have a minimal impact from a health standpoint. Spindle speed is demonstrated to have a dominating effect on both mist mass concentration and aerodynamic particle size.