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Example (inch, coarse): For size 7 ⁄ 16 (this is the diameter of the intended screw in fraction form)-14 (this is the number of threads per inch; 14 is considered coarse), 0.437 in × 0.85 = 0.371 in. Therefore, a size 7 ⁄ 16 screw (7 ⁄ 16 ≈ 0.437) with 14 threads per inch (coarse) needs a tap drill with a diameter of about 0.371 inches.
Drill bit sizes are written as irreducible fractions. So, instead of 78/64 inch, or 1 14/64 inch, the size is noted as 1 7/32 inch. Below is a chart providing the decimal-fraction equivalents that are most relevant to fractional-inch drill bit sizes (that is, 0 to 1 by 64ths).
where is the tap drill size, is the major diameter of the tap (e.g., 3 ⁄ 8 in for a 3 ⁄ 8-16 tap), and / is the thread pitch (1 ⁄ 16 inch in the case of a 3 ⁄ 8-16 tap). For a 3 ⁄ 8-16 tap, the above formula would produce 5 ⁄ 16, which is the correct tap drill diameter. The above formula ultimately results in an approximate 75% thread.
The inserts come in various sizes that range from 7 ⁄ 16 to 2.5 inches (11 to 64 mm). The tool holder usually has a coolant passage running through it. [ 13 ] They are capable of cutting to a depth of about 10 times the bit diameter.
pipe size Thread density Thread pitch P Hand-tight engagement [6] Effective thread [6] Overall length L 4 [6] Actual outside diameter D Tap drill; Length L 1 Turns Diameter E 1 Length L 2 Turns Diameter E 2; inch inch −1 inch mm inch inch inch inch inch inch mm inch mm 1 ⁄ 16: 27 0.03703704 0.9407 0.1600: 4.32: 0.28118 0.2611: 7.05: 0.2875 ...
75% tap drill size (in) (mm) (in −1) (mm) ... This leads to instances where for example, a spanner marked 7 ⁄ 16 BSF is the same size as one marked 3 ...
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In other words the threadform is intentionally truncated by, for example, drilling the minor diameter a bit large with the larger of two possible tap drills. For example, using a 27/64 (.421) as tap drill for ½-13 yields 75% threads (or thereabouts). Using a 7/16 (.437) as tap drill for ½-13 yields 60% threads (or thereabouts).
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