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An ASME B18.2.1 compliant cap screw has somewhat tighter tolerances than a hex bolt for the head height and the shank length. The nature of the tolerance difference allows an ASME B18.2.1 hex cap screw to always fit where a hex bolt is installed but a hex bolt could be slightly too large to be used where a hex cap screw is designed in. Fine ...
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.
The tapped hole (or nut) into which the screw fits, has an internal diameter which is the size of the screw minus the pitch of the thread. Thus, an M6 screw, which has a pitch of 1 mm, is made by threading a 6 mm shank, and the nut or threaded hole is made by tapping threads into a hole of 5 mm diameter (6 mm − 1 mm).
A metric ISO screw thread is designated by the letter M followed by the value of the nominal diameter D (the maximum thread diameter) and the pitch P, both expressed in millimetres and separated by a dash or sometimes the multiplication sign, × (e.g. M8-1.25 or M8×1.25).
US tap and drill bit size and reference chart [7] Machine screw size Number of threads per inch (TPI) Major diameter Minor diameter Tap drills Clearance drill 75% thread for aluminum, brass, & plastics 50% thread for steel, stainless, & iron Close fit Free fit Drill size Decimal equiv. Drill size Decimal equiv. Drill size Decimal equiv. Drill size
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.