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Many thread sizes have several possible tap drills, because they yield threads of varying thread depth between 50% and 100%. Usually thread depths of 60% to 75% are desired. People frequently use a chart such as this to determine the proper tap drill for a certain thread size or the proper tap for an existing hole.
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.
Thread limit or pitch diameter limit is a standard used for classifying the tolerance of the thread pitch diameter for taps. For imperial, H or L limits are used which designate how many units of 0.0005 inch over or undersized the pitch diameter is from its basic value, respectively.
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). Irwin-Hanson says that 60% threads are recommended generally because they give about 90% of the potential holding power of the threadform.
The Unified Thread Standard (UTS) defines a standard thread form and series—along with allowances, tolerances, and designations—for screw threads commonly used in the United States and Canada. It is the main standard for bolts, nuts, and a wide variety of other threaded fasteners used in these countries.
Unified Miniature Screw Threads: V Thread Form: 0.60 UNM ANSI/ASME B1.11-1958 (R2016) Microscope Objective Thread: V Thread Form ASME B1.13M-2005 (R2015) Metric Screw Threads: M Profile: V Thread Form ASME B1.15-1995 (R2003) Unified Inch Screw Threads (UNJ Thread Form) V Thread Form ASME B1.20.1-2013: Pipe Threads, General Purpose (Inch) Pipe ...
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Self-tapping screws can be divided into two classes: [3] those that displace material (especially plastic and thin metal sheets) without removing it, known as "thread-forming" self-tapping screws, and self-tappers with sharp cutting surfaces that remove the material as they are inserted, termed "thread-cutting" self-tapping screws.