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Below is a comprehensive drill and tap size chart for all drills and taps: Inch, imperial, and metric, up to 36.5 millimetres (1.44 in) in diameter. In manufactured parts, holes with female screw threads are often needed; they accept male screws to facilitate the building and fastening of a finished assembly.
The original trapezoidal thread form, and still probably the one most commonly encountered worldwide, with a 29° thread angle, is the Acme thread form (/ ˈ æ k m iː / AK-mee). The Acme thread was developed in 1894 as a profile well suited to power screws that has various advantages over the square thread , [ note 1 ] which had been the form ...
In the case of female threads, tap drill charts typically specify sizes that will produce an approximate 75% thread. A 60% thread may be appropriate in cases where high tensile loading will not be expected. In both cases, the pitch diameter is not affected. The balancing of truncation versus thread strength is similar to many engineering ...
where is the tap drill size, is the major diameter of the tap (e.g., 10 mm for a M10×1.5 tap), and pitch is the pitch of the thread (1.5 mm in the case of a standard M10 tap) and so the correct drill size is 8.5 mm. This works for both fine and coarse pitches, and also produces an approximate 75% thread.
Because only 5 ⁄ 8 of this height is cut, the difference between major and minor diameters is 5 ⁄ 4 × 0.8660 × P = 1.0825 × P, so the tap drill size can be approximated by subtracting the thread pitch from the major diameter.
To calculate the major diameter of "aught" size screws count the number of extra zeroes and multiply this number by 0.013 in and subtract from 0.060 in. For example, the major diameter of a #0000 screw is 0.060 in − (3 × 0.013 in) = 0.060 in − 0.039 in = 0.021 in.
One aspect of this method of sizing is that the size increment between drill bits becomes larger as bit sizes get smaller: 100% for the step from 1/64 to 1/32, but a much smaller percentage between 1 47/64 and 1 3/4. 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.
The two columns following the screw/tap size give the sizes of drills used to make clearance holes for that screw size; and while they list decimal diameters, what they should list is the nomenclature of the indicated drill: it's far more useful to know that a clearance drill is #73 than that it is .024 inches in diameter.
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