The chip removal structure is very important in deep-hole machining and has great influence on drilling efficiency. The method of CAD/CFD is presented to optimize design parameters of the chip removal structure in the paper. Because the shape of front nozzle in the chip removal structure is the key, so the radius of front nozzle is chosen to be an optimized object. Then, the CAD technology is applied to build a series of three-dimensional parameterization models of the chip removal structure with different front nozzle radius, and CFD software FLUENT is used to calculate three-dimensional flow field in the every built model. Subsequently, several evaluation indexes which can indicate performance of the chip removal structure are established and the calculation results of every inner flow field in the model are evaluated by the synthesis of Analytic Hierarchy Process and Fuzzy Comprehensive Evaluation. Finally, the chip removal structure with optimum front nozzle radius is achieved.© (2010) COPYRIGHT SPIE--The International Society for Optical Engineering. Downloading of the abstract is permitted for personal use only.