Appearance
Programming a deep hole drilling operation is fundamentally different from programming a standard drilling cycle. The tool may be 100× or 200× longer than its diameter. Chip evacuation cannot rely on flutes alone — it requires high-pressure coolant, controlled pecking, or continuous cutting with modulated feed. The CAM system must manage pilot hole entry, guide bushing clearance, cross-hole detection, and variable cutting conditions along the hole length. Choosing the right CAM software is as important as choosing the right machine.
Why Deep Hole Drilling Demands Special CAM Features
The Limits of Standard Canned Cycles
Most CAM systems support the standard G83 (deep hole peck) and G73 (chip break) canned cycles. For true deep hole drilling — particularly BTA and gun drilling — these cycles are insufficient:
| Limitation | Why It Matters for Deep Hole Drilling |
|---|---|
| Fixed peck depth (Q) | Cannot vary peck increment as depth increases and chip evacuation becomes harder |
| Full retract to R-plane | Washing coolant down the hole can destabilize chip evacuation; gun drills should never fully retract mid-hole |
| No pilot hole entry | Tool enters material unsupported — a direct cause of edge chipping and bell mouth |
| No cross-hole detection | Tool impacts the opposite wall of a cross-hole at full feed, causing 5–10× force spikes |
| No coolant modulation | Cannot vary coolant pressure or flow during the cycle |
| No spindle speed variation | Cannot reduce RPM at entry or breakthrough |
Recommended Methods by Depth Ratio
| Depth-to-Diameter Ratio | Recommended Method | CAM Cycle |
|---|---|---|
| 0–3× | Standard drilling | G81 simple drill |
| 3–5× | Peck drilling | G83 or G73 with fixed peck |
| 5–10× | Peck drilling with variable peck | G83 with custom Q reduction |
| 10–20× | Custom deep hole cycle (parametric) | Machine-specific or custom macro |
| 20–100× | Gun drilling | Continuous feed with high-pressure coolant; CAM with pilot entry support |
| 100×+ | BTA / STS / Ejector drilling | Specialized CAM with cross-hole detection, zone feed control |
Mastercam
| Detail | Information |
|---|---|
| Developer | CNC Software, Inc. (USA) |
| Deep hole support | Custom drill cycles via post-processor customization |
| Best for | General machining, job shops, custom macro integration |
| Website | mastercam.com |
Mastercam does not include a dedicated "gun drilling" or "BTA drilling" operation type. Instead, deep hole drilling is handled through:
Standard drilling cycles:
- G83 (Deep Hole Peck Drill) — full retract to R-plane
- G73 (Chip Break) — short retract
- Custom cycles (8–19) — defined in the post-processor
Custom cycle approach (most common for gun drilling): The Mastercam user community has developed custom post-processor macros that:
- Feed into a pilot hole at low RPM
- Increase spindle speed to cutting RPM
- Activate through-spindle coolant (TSC)
- Drill to depth with variable peck increments
- Reduce spindle speed before retract
- Deactivate coolant and retract
Key post variables used:
| Variable | Function |
|---|---|
drillcyc$ | Cycle type (0=simple, 1=peck, 8-19=custom) |
peck1$ | First peck increment |
peck2$ | Subsequent peck increments |
peckclr$ | Clearance above previous peck depth |
drl_prm1$ – drl_prm6$ | User-defined custom parameters |
Limitations:
- No dedicated gun drilling interface — requires post-processor programming
- No automatic cross-hole detection
- No built-in pilot hole entry logic
- Relies on the programmer to manage chip evacuation strategy manually
Best suited for: Job shops that use gun drilling occasionally and can invest in custom post-processor development.
Siemens NX CAM
| Detail | Information |
|---|---|
| Developer | Siemens Digital Industries Software (Germany/USA) |
| Deep hole support | Dedicated Deep Hole Drilling operation subtype (since NX 10.0.2 / NX 11) |
| Best for | High-end manufacturing, aerospace, automotive production |
| Website | siemens.com/nx |
Siemens NX CAM is the only major CAM system with a dedicated deep hole drilling operation type specifically designed for gun drilling and BTA processes.
Key features:
- Pilot hole support: The tool rapids through the pilot hole to a control point, then engages at a specified feed rate
- Control Point parameter: Choose between In-Process Feature (rapid through pilot) or Machining Feature (rapid to feature, then engage feed)
- Cross-hole detection: Automatically detects cross holes and controls feed rate at intersections to avoid tool damage
- Zone-based feed control: Separate feed rates for entry, cutting, and exit zones
- Chip break integration: Combines deep drilling with chip-breaking functionality
- First Cut / Last Cut control: Feed slows to 50% at entry and reduces at breakthrough
Motion and event control:
| Phase | Parameters |
|---|---|
| Engage conditions | Spindle speed, coolant control through pilot hole |
| Cut conditions | Feed rate, coolant, spindle behavior during cutting |
| Retract conditions | Separate settings for At Bottom and At Top; Bottom Release Distance |
Siemens claims up to 60% reduction in NC programming time for hole-making operations compared to traditional methods.
Best suited for: Aerospace, automotive, and energy companies that already use the Siemens PLM ecosystem and need production-ready deep hole drilling support.
hyperMILL (Open Mind Technologies)
| Detail | Information |
|---|---|
| Developer | Open Mind Technologies (Germany) |
| Deep hole support | Dedicated gun drilling cycle, optimized deep hole drilling (2024 release) |
| Best for | High-complexity 5-axis, mold and die, aerospace |
| Website | openmind-tech.com |
hyperMILL offers a dedicated Gun Drilling operation within its 2.5D drilling strategy set. The 2024 release introduced an optimized deep hole drilling strategy with significant enhancements.
Key features:
- Single-tip gun drill tool simulation: Precise collision checking with detailed stock removal visualization
- Regional feed rate control: Feed rates, spindle RPM, and coolant can be controlled separately for:
- Guide bushing zone
- Pilot hole entry
- Cross-hole intersections
- Main cutting zone
- Breakthrough zone
- Automatic cross-hole detection: Based on specified stock model to prevent tool damage
- Chip breaker integration: Combined with deep hole drilling process
- Coolant and dwell control: New process tab with clearly defined coolant and dwell time stages
- Automatic hole recognition: All hole types reliably recognized as features
2024 release enhancements:
- Optimized deep hole drilling CAM strategy
- CAM Plan programming assistance module for guided workflow
- Macro technology for automated programming of hundreds of holes
Best suited for: Companies running 5-axis machines that need sophisticated deep hole drilling support with full simulation and collision checking.
Autodesk Fusion 360
| Detail | Information |
|---|---|
| Developer | Autodesk (USA) |
| Deep hole support | Standard drilling cycles; no dedicated gun drilling operation |
| Best for | Small to medium shops, integrated CAD/CAM, hobbyist to professional |
| Website | autodesk.com/fusion-360 |
Fusion 360 supports standard drilling cycles (G81, G83, G73) within its CAM environment but does not include a dedicated gun drilling or BTA operation.
Available drilling cycles:
- Simple drilling (G81)
- Deep hole peck (G83) — full retract
- Chip break (G73) — partial retract
- Custom cycles via post-processor
Limitations:
- No pilot hole entry logic
- No cross-hole detection
- No dedicated gun drill tool model
- No zone-based feed or speed control
- Relies on post-processor for any custom behavior
Strengths:
- Integrated CAD/CAM eliminates file translation
- Cloud-based collaboration
- Regular updates with new features
- Growing library of post-processors
Best suited for: Small to medium shops that need an affordable, integrated CAD/CAM solution for occasional deep hole drilling jobs.
ESPRIT (DP Technology / Hexagon)
| Detail | Information |
|---|---|
| Developer | DP Technology / Hexagon (USA) |
| Deep hole support | Comprehensive drilling cycles; strong turning/multi-tasking support |
| Best for | Multi-tasking machines, Swiss-type lathes, mill-turn |
| Website | dptechnology.com |
ESPRIT provides a comprehensive set of drilling cycles suitable for deep hole operations, particularly strong in the context of multi-tasking and Swiss-type machining.
Key features:
- Full range of drilling cycles including peck drilling with variable increments
- Strong support for live tooling and driven tools on lathes
- Custom cycle support via post-processor and user-defined cycles
- High-pressure coolant control integration
- Solid simulation with tool checking
Strengths for deep hole drilling:
- Excellent for Swiss-type lathe gun drilling (common in medical and aerospace)
- Multi-channel synchronization for simultaneous operations
- Extensive post-processor library with support for custom macros
- Strong collision detection during simulation
Best suited for: Shops running Swiss-type lathes or multi-tasking machines where deep hole drilling is performed on turned parts.
CAMWorks (HCL Technologies)
| Detail | Information |
|---|---|
| Developer | HCL Technologies (India/USA) |
| Deep hole support | Deep hole peck drilling operations; automatic feature recognition |
| Best for | SolidWorks-integrated manufacturing |
| Website | camworks.com |
CAMWorks operates natively within SolidWorks, offering associative CAM that updates automatically with design changes. The 2016 release introduced enhanced deep hole drilling support.
Key features:
- Deep hole peck drilling operation with customizable parameters
- Automatic feature recognition (AFR) for hole features
- Technology database with recommended parameters by material
- SolidWorks integration for design-associative toolpaths
- Post-processor support for custom drilling cycles
Best suited for: SolidWorks users who want integrated CAM with automatic feature recognition and associative toolpaths.
FeatureCAM / Autodesk PowerMILL
| Detail | Information |
|---|---|
| Developer | Autodesk (USA) |
| Deep hole support | Feature-based drilling with knowledge-based automation |
| Best for | Automated programming, feature recognition |
FeatureCAM (now part of Autodesk's manufacturing portfolio) uses feature-based programming with extensive drilling cycle support. Its strength lies in automatic feature recognition and knowledge-based machining — the system can automatically select appropriate drilling strategies based on hole geometry.
PowerMILL is primarily a 5-axis CAM system but includes comprehensive drilling support for complex multi-axis hole making, including deep hole cycles.
Comparison Table
Deep Hole Drilling Feature Comparison
| Feature | Mastercam | NX CAM | hyperMILL | Fusion 360 | ESPRIT | CAMWorks |
|---|---|---|---|---|---|---|
| Dedicated gun drill cycle | No (custom post) | Yes | Yes | No | No | No |
| Pilot hole entry logic | Custom post | Yes | Yes | No | Custom post | No |
| Cross-hole detection | No | Yes | Yes | No | No | No |
| Variable peck depth | Custom macro | Yes | Yes | No | Custom macro | Partial |
| Zone-based feed/speed | Custom post | Yes | Yes | No | Custom post | No |
| Single-tip gun drill simulation | No | Yes | Yes | No | No | No |
| Coolant modulation | Custom post | Yes | Yes | Custom post | Custom post | Custom post |
| Breakthrough feed control | Custom post | Yes | Yes | No | Custom post | No |
| Autodesk/CAM integration | CAD import | Full PLM | CAD import | Integrated CAD/CAM | CAD import | SolidWorks native |
| Post-processor flexibility | High | High | High | Moderate | High | High |
Ease of Deep Hole Programming
| System | Programming Effort | Best Deep Hole Application |
|---|---|---|
| Mastercam | Requires custom post | Job shops with occasional gun drilling |
| Siemens NX CAM | Minimal (dedicated operation) | Production gun drilling and BTA |
| hyperMILL | Minimal (dedicated cycle) | 5-axis gun drilling with complex geometry |
| Fusion 360 | Moderate (manual G-code adjustments) | Simple deep holes on a budget |
| ESPRIT | Low-Moderate | Swiss-type and mill-turn deep hole drilling |
| CAMWorks | Moderate (AFR-assisted) | SolidWorks-centric operations |
Post-Processor Considerations
Deep hole drilling CAM programming is only as good as the post-processor. Even the best CAM system cannot produce correct deep hole code without a properly configured post.
Critical Post-Processor Requirements for Deep Hole Drilling
| Requirement | Why It Matters |
|---|---|
| Custom drill cycle support | Standard G83/G73 is insufficient for BTA/gun drilling |
| Coolant M-code control | High-pressure coolant must turn on/off at specific cycle phases |
| Spindle speed override per zone | Entry, cutting, and retract may require different RPM |
| Feed rate modulation | Variable feed for pilot, cutting, cross-hole, and breakthrough zones |
| Subprogram/Macro call support | Long deep hole cycles exceed control memory; macros are required |
| Dwell control | Chip breaking may require dwell at specific depths |
Post-Processor Strategy by CAM System
| CAM System | Post Approach |
|---|---|
| Mastercam | Customize MP post with custom drill cycle (drillcyc$ 8-19) |
| NX CAM | Use NX Post Builder with event-driven deep hole drill events |
| hyperMILL | Use hyperMILL post interface; dedicated gun drill events |
| Fusion 360 | Edit Fusion 360 post with custom cycle template |
| ESPRIT | Use ESPRIT G-Code generator with custom cycle definitions |
TIP
If you are serious about deep hole drilling production, invest in a properly customized post-processor for your specific CAM system and machine control combination. A generic post-processor will not handle the demands of BTA or gun drilling programming. Most CAM vendors offer post-processor customization services, or you can work with a third-party post specialist.
Selection Guide
By Machine Type
| Machine Type | Recommended CAM | Reason |
|---|---|---|
| Gun drilling machine (dedicated) | NX CAM or hyperMILL | Dedicated cycles, pilot entry, cross-hole detection |
| BTA drilling machine (dedicated) | NX CAM | Zone-based feed control, deep hole operation |
| Machining centre with gun drilling | Mastercam or hyperMILL | Flexible, custom post options |
| Swiss-type lathe with gun drilling | ESPRIT | Multi-channel, live tooling support |
| Mill-turn with deep hole drilling | ESPRIT or NX CAM | Multi-tasking, synchronized operations |
| Job shop, occasional deep holes | Fusion 360 or Mastercam | Lower cost, adequate for simple jobs |
By Production Volume
| Volume | Recommended CAM | Justification |
|---|---|---|
| Prototype / low volume | Fusion 360 or Mastercam | Lower investment, flexible |
| Medium volume | Mastercam or CAMWorks | Reliable, established workflows |
| High volume production | NX CAM or hyperMILL | Automation, cross-hole detection, zone control |
By Industry
| Industry | Recommended CAM | Why |
|---|---|---|
| Aerospace | NX CAM or hyperMILL | Cross-hole detection, 5-axis support, traceability |
| Automotive production | NX CAM | High-volume, automated, PLM integration |
| Medical (Swiss-type) | ESPRIT | Swiss machining, small diameters, high precision |
| Oil and gas | NX CAM or hyperMILL | Large diameters, deep holes, BTA |
| Mold and die | hyperMILL | 5-axis drilling in complex geometries |
| General job shop | Mastercam or Fusion 360 | Cost-effective, widely supported |
FAQ
Q: What CAM software has the best deep hole drilling support? Siemens NX CAM and hyperMILL (Open Mind) have the most comprehensive deep hole drilling features, including dedicated gun drilling cycles, pilot hole entry logic, cross-hole detection, and zone-based feed/speed control.
Q: Can Mastercam program gun drilling operations? Yes, but it requires custom post-processor programming. Mastercam does not include a dedicated gun drilling operation type. The user community has developed custom macros that handle variable peck depths, RPM modulation, and coolant control.
Q: Is G83 suitable for BTA drilling? No. G83 (deep hole peck cycle) is designed for twist drills, not BTA or gun drilling. BTA tools require continuous cutting with high-pressure coolant. Full retracts can destabilize chip evacuation and damage the cutting edge.
Q: Do I need special CAM for deep hole drilling? For simple deep holes (up to 10× diameter) with twist drills, standard CAM with G83/G73 is sufficient. For BTA or gun drilling at ratios exceeding 20× diameter, a CAM system with dedicated deep hole features (NX CAM, hyperMILL) or a properly customized post-processor is strongly recommended.
Q: What is the most affordable CAM option for deep hole drilling? Autodesk Fusion 360 offers the lowest entry price with adequate drilling cycle support for occasional deep hole work. However, for production deep hole drilling, the investment in NX CAM or hyperMILL is justified by reduced programming time and improved process reliability.
Q: How important is post-processor customization for deep hole drilling? Critical. A generic post-processor cannot generate the custom cycle code required for BTA or gun drilling. The post-processor must handle coolant M-code control, variable feed rates, spindle speed modulation, and subprogram/macro calls.
Q: Does hyperMILL support single-tip gun drill simulation? Yes. The hyperMILL 2024 release added single-tip gun drill tool simulation for precise collision checking and detailed stock removal visualization.
Q: Can Fusion 360 handle cross-hole detection? No. Fusion 360 does not include automatic cross-hole detection for drilling operations. The programmer must manually identify cross-holes and adjust feed rates in the program.
Q: Which CAM system is best for Swiss-type lathe gun drilling? ESPRIT (DP Technology/Hexagon) is widely considered the best CAM system for Swiss-type lathes, with strong support for gun drilling cycles, multi-channel synchronization, and live tooling operations.
Q: Is CAMWorks good for deep hole drilling? CAMWorks provides adequate deep hole peck drilling support with automatic feature recognition, but it lacks dedicated gun drilling cycles, cross-hole detection, and zone-based feed control found in NX CAM and hyperMILL.