This paper presents the analytical approaches to predict cutting fluid aerosol formation characteristics in machining process. The prediction model which is based on the rotary atomization theory analyzes aerosol behaviors in terms of size and concentration. Experiments were tarried out to verify the aerosol formation prediction model under various operational conditions. The experimental results which are obtained by Dual-PDA measurement show resonable agreement with prediction results of aerosol concentration. This study can be provided as a basis to estimate and control the hazardous cutting fluid aerosol in machining process in view of environmental consciousness.