170 PD0193ManufacturingStandardReferenceGuideRev3

Document No.
PD0193 REV 3
Automotive Service Solutions QMS
Manufacturing
Table of Contents
General Manufacturing Tolerances................................................................................................................................. 2
INSPECTION AFTER FINISH COATINGS: Unless otherwise noted, all dimensional tolerance to machined surfaces
will apply after finish coatings are applied. This includes paint......................................................................................2
Straightness Standard for all Heat Treated Parts: The following are maximum permissible straightness tolerances
for these groups of parts unless otherwise specified. .....................................................................................................2
Manufacturing Standards for Blend ................................................................................................................................ 3
Angles 5................................................................................................................................................................. 3
External Chamfer on Threads......................................................................................................................................... 4
A (see table) X 45 ....................................................................................................................................................... 4
Chamfer on Squares, Hexagons & Octagons.................................................................................................................5
Countersink on a curved surface .................................................................................................................................... 5
Countersinks on Internal Straight Threads .....................................................................................................................6
Recommended External Thread Relief...........................................................................................................................6
A & B Drill Tolerance Table............................................................................................................................................ 7
Center Drills .................................................................................................................................................................... 7
A & B Tolerances for Fraction and Letter drilled holes ..................................................................................................8
A & B Tolerances for Metric drilled holes......................................................................................................................10
A & B Tolerances for Numbered drilled holes..............................................................................................................12
Sandvik T-MAX U Drill bottom profile ...........................................................................................................................14
Fraction conversions..................................................................................................................................................... 15
Conversion Table.......................................................................................................................................................... 16
Millimeters to Inches ..................................................................................................................................................... 16
Hardness Conversion Tables for steel and hard alloys ................................................................................................17
Gauge and Wire Conversion - Decimals of an inch ......................................................................................................18
Decimal Equivalents Conversions ................................................................................................................................ 19
SI - The Metrics International System of Units..............................................................................................................21
Conversion Factors....................................................................................................................................................... 21
Length Conversion Factors........................................................................................................................................... 22
Area Conversion Factors .............................................................................................................................................. 22
Volume Conversion Factors.......................................................................................................................................... 22
Force Conversion Factors............................................................................................................................................. 22
Pressure or Stress Conversion Factors ........................................................................................................................22
Mass (weight) Conversion Factors ............................................................................................................................... 22
Temperature Conversion Factors ................................................................................................................................. 23
Power Conversion Factors............................................................................................................................................ 23
Sheet Metal Conversion Factors................................................................................................................................... 23
More Useful Conversion Factors .................................................................................................................................. 24
Knurling......................................................................................................................................................................... 25
Manufacturing Allowance for Holes .............................................................................................................................. 26
Acceptance Standard for Thermally Cut Product .........................................................................................................26
Purpose......................................................................................................................................................................... 27
Scope............................................................................................................................................................................ 27
Definitions and Acronyms ............................................................................................................................................. 27
Documents, Forms and Equipment .............................................................................................................................. 27
General Requirements.................................................................................................................................................. 27
General Specifications .................................................................................................................................................. 29
Instructions for setting a Bite Type ferrule. Ref Drawing 516398. ...............................................................................34
Print Date: August 31, 2016
Automotive Service Solutions

QMS electronic document is the controlled copy
Page 1 of 34
Document No. PD0193 REV 3
General Manufacturing Tolerances

The following standards may be used only when applicable feature or tolerance is not specified on the
drawing.
Geometric Features:
Note: Parts must remain within size and tolerance envelopes
Parallelism:
Machining or Grinding
Rough Cutting
. 01 mm per 5 linear mm (.002 per linear inch)

. 1 mm per 10 linear mm (.010 per linear inch)
Perpendicularly, Angularity & Chamfers:

Machined (with specified RMS on the chamfer or angle)
Machined (w/o specified RMS on the chamfer or angle)
Rough (hand belting, c/r, on the chamfer or angle)
Welding
Rough cutting (saw, flamecut, Laser etc.)
2
5
10
2
2
Roundness: For hollow (cylindrical) parts only due to the variety of size vs. tolerance vs. Wall
thickness vs. application no general guideline will be established. Problem parts must be brought to
Design Engineering for review and possible drawing change and/or deviation.
Runout: Unspecified runout is .25mm (.010) total maximum (applies to outside diameters that are cold
finished and to all machined diameters.)
Concentricity: (use runout)
Centerline: Unspecified centerline tolerance is .38mm (.015). (Note: runout takes precedence over
this standard)
Fractional Dimension:
1. Saw
2. Punch
3. All Other
4. Weldment
Untoleranced fractional dimensions will be inspected per the following:

+/- .75mm (.032)
+/- .38mm (.015) (Also See Sheared Edge Specification)
+/- .38mm (.015)
+/- 1.50mm (.062)
Corner Breaks:
Unless otherwise noted, all outside corner breaks to be .05mm / .50mm (.002 /. 020.)
Flame Cut: Unless otherwise noted flame cut tolerances to be 1.5mm (.060).
INTERNAL RADII: Unless otherwise noted, all internal radii at surface intersection to be .00mm /
1.00mm (.000 /.040) R. except for HEAT TREATED parts. (Including case hardened parts)
INTERNAL RADII ON ALL HEAT TREATED PARTS: Unless otherwise noted, all internal radii to be .38mm /
1.00mm (.015 /.040) R.
INSPECTION AFTER FINISH COATINGS: Unless otherwise noted, all dimensional tolerance to
machined surfaces will apply after finish coatings are applied. This includes paint.
Straightness Standard for all Heat Treated Parts: The following are maximum permissible
straightness tolerances for these groups of parts unless otherwise specified.
1. Forcing screws and ram adjusting screws --- .50mm / 300mm (.020/ 12.)
2. Push puller legs --- .75mm / 300mm (.030/ 12).
3. Puller cross block (slotted type) --- 1.50mm / 300mm (.060/ 12).
4. Pry bars --- 1.50mm / 300mm (.060/ 12).
5. Distributor wrenches --- 2.25mm / 300mm (.090/ 12).
6. Puller Jaws --- .12mm / 300 (.045/ 12).

Page 2 of 34
Manufacturing Standards for Blend

Unless otherwise noted, the "BLEND" designation on a corner requires the intersection of the
surfaces to be rounded slightly (up to 2mm (.080) radius max.) to remove any detectable
sharpness. The rounding can be done either by generating a machined fillet or by polishing.
INSPECTION
The method of inspection shall be to feel for a detectable edge or burr, in the BLEND area with a
fingernail or sharp probe. A detectable edge or burr is sufficient for rejection
Blend
Borroughs Manufacturing Standards

(for Borroughs Title Block Drawings Only)
(UNLESS OTHERWISE SPECIFIED)
Tolerances:
Fractions
One Place Decimal
Two Place Decimal
Three Place Decimal
Angles
Corner Breaks
Surface Finish
.75mm
( .030)
1.50mm
( .060)
.75mm
( .030)
.25mm
( .010)
5
.05mm / .50mm
(.002 /.020)
250
Standard Hole Tolerances and Surface Finish Standards

Apply Unless Otherwise Specified.
Case Harden
To specify for Wear Resistance note as:
CASE HARDEN .12mm (.005) MIN. EFFECTIVE DEPTH.
To specify for Medium Wear Resistance and Light Load note as:
To specify for High Wear Resistance and High Load note as:

Page 3 of 34
External Chamfer on Threads

25 - 35
A (see table) X 45
Notes: 1) Lead chamfer on rolled threads is 25-35
2) Shafts must be chamfered before threading unless shown otherwise on the drawing.
SAE
Threads
Per Inch
4
4
5
6
7
8
9
10
11
12
A = mm
+.5mm - .000
4.2
3.7
3.4
2.9
2.5
2.3
2.0
1.8
1.6
1.5
A = inches
+.020 -.000
.165
.145
.135
.115
.100
.090
.080
.070
.065
.060
Threads
Per Inch
13
14
16
18
20
24
28
32
36
40
A = mm
+.5mm - .000
1.5
1.4
1.3
1.1
1.0
.90
.75
.75
.65
.60
A = inches
+.020 -.000
.060
.055
.050
.045
.040
.035
.030
.030
.027
.025
A = mm
+.5mm - .000
1.3
1.5
1.8
2.1
2.4
2.7
3.0
3.3
3.6
3.9
A = inches
+.020 -.000
.050
.060
.070
.080
.095
.105
.120
.130
.140
.155
Metric
Metric Thread
Pitch
.35
.4
.45
.5
.6
.7
.75
.8
1
1.25
1.5
A = mm
+.5mm - .000
.4
.4
.5
.5
.5
.6
.6
.6
.8
1.0
1.1
A = inches
+.020 -.000
.015
.015
.020
.020
.020
.025
.025
.025
.030
.040
.043
Metric Thread
Pitch
1.75
2
2.5
3
3.5
4
4.5
5
5.5
6

Page 4 of 34
Chamfer on Squares, Hexagons & Octagons

All chamfers shown on squares, hexagons & octagons must be made to the
dimensions shown below unless otherwise specified.
30 +/- 10
DIST. ACROSS FLATS
LESS THAN 13mm (.500)
13mm 25mm (.500-1.000)
OVER 25mm (1.000)
A
.75mm (.030)
1.50mm (.060)
2.25mm (.090)
Countersink on a curved surface
NOTE: Chamfer must meet minor diameter on short side and can go over on long.

Page 5 of 34
Countersinks on Internal Straight Threads

On internal straight threads all holes must be countersunk before threading
(tapping) unless otherwise shown on the drawing.
Note: For cast or forged surfaces, tolerance 'A' is for ref. Only
NOMINAL THREAD DIA.

0 <6mm
(0 - .249)
6mm - <13mm (.250 - .499)
13mm - <22mm (.500 - .874)
22mm - <32mm (.875 - 1.250)
Larger than 32mm (1.250)
A + to +
.25mm to .75mm (.010 to .030)
.50mm to 1.00mm (.020 to .040)
.75mm to 1.25mm (.030 to .070)
.75mm to 2.00mm (.030 to .080)
.75mm to 2.25mm (.030 to .090)
Recommended External Thread Relief

-.12mm to -.38mm

Page 6 of 34
A & B Drill Tolerance Table

(Refer to A & B tolerance charts on the following pages)
DRILL
DIA.
Thru.
1.50mm (.062)
Over
Thru.
Over
Thru.
Over
Thru.
Over
Thru.
1.50mm (.062)
6.3mm (.250)
6.3mm (.250)
12.7mm (.500)
12.7mm (.500)
19.0mm (.750)
19.0mm (.750)
25.4mm (1.000)
Over
25.4mm (1.000)
+.08mm -.02mm
(+.003 -.001)
+.12mm - .02mm
(+.005 -.001)
+.15mm - .02mm
(+.006 -.001)
+.20mm - .05mm
(+.008 -.002)
+.25mm - .05mm
(+.010 -.002)
+.25mm - .075mm
(+.010 -.003)
+.08mm - .02mm
(+.003 -.001)
+.25mm - .10mm
(+.010 -.004)
+.30mm - .10mm
(+.012 -.004)
+.38mm - .15mm
(+.015 -.006)
+.50mm - .15mm
(+.020 -.006)
+.50mm - .25mm
(+.020 -.010)
NOTE:
1. Tolerance 'A' must apply to all tap drills unless otherwise noted.
2. Tolerance 'B' applies to all other drilled holes unless otherwise noted.
3. The general finish note for machined surfaces does not apply to drilled or tapped holes
unless otherwise specified.
4. Unless otherwise specified, all holes identified as drill to be 118 Included angle.
5. All older Kent-Moore drawings prior to Feb-88 use class A drill if not specified.
Center Drills
American Standard Combined Drills and Countersinks, Plain, and Bell Types
Body
Diam.
Drill
Diam.
Drill
Length
Overall
Length
1/8
3.17mm
3/16
4.75mm
3/64
1.19mm
5/64
1.98mm
3/64
1.19mm
5/64
1.98mm
1 1/4
31.75mm
1 7/8
47.62mm
Body
Diam.
Drill
Diam.
Drill
Length
Overall
Length
1/4
6.35mm
5/16
7.92mm
7/16
11.10mm
1/2
12.7mm
7/64
2.78mm
1/8
3.17mm
3/16
4.75mm
7/32
5.55mm
7/64
2.78mm
1/8
3.17mm
3/16
4.75mm
7/32
5.55mm
2
50.8mm
2 1/8
53.97mm
2 3/4
69.85mm
3
76.20mm
Size
Body
Diam.
Drill
Diam.
Drill
Length
Overall
Length
Bell
Diam.
1/8
3.17mm
3/16
4.75mm
3/64
1.19mm
5/64
1.98mm
3/64
1.19mm
5/64
1.98mm
1 1/4
31.75mm
1 7/8
47.62mm
0.100
2.54mm
0.150
3.81mm
Body
Diam.
Drill
Diam.
Drill
Length
Overall
Length
Bell
Diam.
1/4
6.35mm
5/16
7.92mm
7/16
11.10mm
1/2
12.7mm
7/64
2.78mm
1/8
3.17mm
3/16
4.75mm
7/32
5.55mm
7/64
2.78mm
1/8
3.17mm
3/16
4.75mm
7/32
5.55mm
2
50.8mm
2 1/8
53.97mm
2 3/4
69.85mm
3
76.20mm
0.200
5.08mm
0.250
6.35mm
0.350
8.89mm
0.400
10.16mm
Size
1
2
11
12
Size
Size
3
4
5
6
13
14
15
16

Page 7 of 34

7
8
5/8
15.87mm
3/4
19.05mm
1/4
6.35mm
5/16
7.92mm
1/4
6.35mm
5/16
7.92mm
3 1/4
82.55mm
3 1/2
88.90mm
17
18
5/8
15.87mm
3/4
19.05mm
1/4
6.35mm
5/16
7.92mm
1/4
6.35mm
5/16
7.92mm
3 1/4
82.55mm
3 1/2
88.90mm
0.500
12.70mm
0.600
15.24mm
All Dimensions except size designation are in inches.

Tolerances: Plus 0 minus 0.002 on A; plus .003 minus 0 on D, plus 1/32 minus 1/16on L; plus 0.008 minus 0.008 on C for
sizes 1, 2, 11, and 12; plus 1/64 minus 1/64 on C for sizes 3, 4, 5, 6, 7, 8, 13, 14, 15, 16, 17, and 18
A & B Tolerances for Fraction and Letter drilled holes

Rounded off to 3 Decimal Places per ANSI Standard Z25.1
HOLE SIZE
1/64
1/32
3/64
1/16
5/64
3/32
7/64
1/8
9/64
5/32
11/64
3/16
13/64
7/32
15/64
1/4
17/64
9/32
19/64
5/16
21/64
11/32
23/64
3/8
25/64
Decimal
0.016
0.031
0.047
0.062
0.078
0.094
0.109
0.125
0.141
0.156
0.172
0.188
0.203
0.219
0.234
0.250
0.266
0.281
0.297
0.312
0.328
0.344
0.359
0.375
0.391
A
.015/.019
.030/.034
.046/.050
.061/.065
.077/.083
.093/.099
.108/.114
.124.130
.140/.146
.155/.161
.171/.177
.187/.193
.202/.208
.218/.224
.233/.239
.249/.255
.265/.272
.280/.287
.296/.303
.311/.318
.327/.334
.343/.350
.358/.365
.374/.381
.390/.397
B
.015/.019
.030/.034
.046/.050
.061/.065
.074/.088
.090/.104
.105/.119
.121/.136
.137/.151
.152/.166
.168/.182
.184/.198
.199/.213
.215/.229
.230/.244
.246/.260
.262/.278
.277/.293
.293/.309
.308/.324
.324/.340
.340/.356
.355/.371
.371/.387
.387/.403

A (mm)
0.38/0.48
0.76/0.86
1.17/1.27
1.55/1.65
1.96/2.11
2.36/2.51
2.74/2.90
3.15/3.30
3.56/3.71
3.94/4.09
4.34/4.50
4.75/4.90
5.13/5.28
5.54/5.69
5.92/6.07
6.32/6.48
6.73/6.91
7.11/7.29
7.52/7.70
7.90/8.08
8.31/8.48
8.71/8.89
9.09/9.27
9.50/9.68
9.91/10.08
B (mm)
0.38/0.48
0.76/0.86
1.17/1.27
1.55/1.65
1.88/2.24
2.29/2.64
2.67/3.02
3.07/3.45
3.48/3.84
3.86/4.22
4.27/4.62
4.67/5.03
5.05/5.41
5.46/5.82
5.84/6.20
6.25/6.60
6.65/7.06
7.04/7.44
7.44/7.85
7.82/8.23
8.23/8.64
8.64/9.04
9.02/9.42
9.42/9.83
9.83/10.24
Page 8 of 34

A & B Tolerances for Fraction and Letter drilled holes (continued)
HOLE SIZE
13/32
27/64
7/16
29/64
15/32
31/64
1/2
33/64
17/32
35/64
9/16
37/64
19/32
39/64
5/8
41/64
21/32
43/64
11/16
45/64
23/32
47/64
3/4
49/64
25/32
51/64
13/16
53/64
27/32
55/64
7/8
57/64
29/32
59/64
15/16
61/64
31/32
63/64
1
B
C
D
F
G
H
I
J
Decimal
0.406
0.422
0.438
0.453
0.469
0.484
0.500
0.516
0.531
0.547
0.562
0.578
0.594
0.609
0.625
0.641
0.656
0.672
0.688
0.703
0.719
0.734
0.750
0.766
0.781
0.797
0.812
0.828
0.844
0.859
0.875
0.891
0.906
0.922
0.938
0.953
0.969
0.984
1.000
A
.405/.412
.421/.428
.437/.444
.452/.459
.468/.475
.483/.490
.499/.506
.514/.524
.529/.539
.545/.555
.560/.570
.576/.586
.592/.602
.607/.617
.623/.633
.639/.649
.654/.664
.670/.680
.686/.696
.701/.711
.717/.727
.732/.742
.748/.758
.764/.776
.779/.791
.795/.807
.810/.822
.826/.838
.842/.854
.857/.869
.873/.885
.889/.901
.904/.916
.920/.932
.936/.948
.951/.963
.967/.979
.982/.994
.998/1.010
B
.402/.418
.418/.434
.434/.450
.449/.465
.465/.481
.480/.496
.496/.512
.510/.531
.525/.546
.541/.562
.556/.577
.572/.593
.588/.609
.603/.624
.619/.640
.635/.656
.650/.671
.666/.687
.682/.703
.697/.718
.713/.734
.728/.749
.744/.765
.760/.786
.775/.801
.791/.817
.806/.832
.822/.848
.838/.864
.853/.879
.869/.895
.885/.911
.900/.926
.916/.942
.932/.958
.947/.973
.963/.989
.978/1.004
.994/1.020
A (mm)
10.29/10.46
10.69/10.87
11.10/11.28
11.48/11.66
11.89/12.07
12.27/12.45
12.67/12.85
3.06/13.31
13.44/13.69
13.84/14.10
14.22/14.48
14.63/14.88
15.04/15.29
15.42/15.67
15.82/16.08
16.23/16.48
16.61/16.87
17.02/17.27
17.42/17.68
17.81/18.06
18.21/18.47
18.59/18.85
19.00/19.25
19.41/19.71
19.79/20.09
20.19/20.50
20.57/20.88
20.98/21.29
21.39/21.69
21.77/22.07
22.17/22.48
22.58/22.89
22.96/23.27
23.37/23.67
23.77/24.08
24.16/24.46
24.56/24.87
24.94/25.25
25.35/25.65
B (mm)
10.21/10.62
10.62/11.02
11.02/11.43
11.40/11.81
11.81/12.22
12.19/12.60
12.60/13.00
12.95/13.49
13.34/13.87
13.74/14.27
14.12/14.66
14.53/15.06
14.94/15.47
15.32/15.85
15.72/16.26
16.13/16.66
16.51/17.04
16.92/17.45
17.32/17.86
17.70/18.24
18.11/18.64
18.49/19.02
18.90/19.43
19.30/19.96
19.69/20.35
20.09/20.75
20.47/21.13
20.88/21.54
21.29/21.95
21.67/22.33
22.07/22.73
22.48/23.14
22.86/23.52
23.27/23.93
23.67/24.33
24.05/24.71
24.46/25.12
24.84/25.50
25.25/25.91
0.238
0.242
0.246
0.257
0.261
0.266
0.272
0.277
.237/.243
.241/.247
.245/.251
.256/.263
.260/.267
.265/.272
.271/.278
.276/.283
.234/.248
.238/.252
.242/.256
.253/.269
.257/.273
.262/.278
.268/.284
.273/.289
6.02/6.17
6.12/6.27
6.22/6.38
6.50/6.68
6.60/6.78
6.73/6.91
6.88/7.06
7.01/7.19
5.94/6.30
6.05/6.40
6.15/6.50
6.43/6.83
6.53/6.93
6.65/7.06
6.81/7.21
6.93/7.34

Page 9 of 34

A & B Tolerances for Fraction and Letter drilled holes (continued)
HOLE SIZE
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
Decimal
0.290
0.295
0.302
0.316
0.323
0.332
0.339
0.348
0.358
0.368
0.377
0.386
0.397
0.404
0.413
A
.289/.296
.294/.301
.301/.308
.315/.322
.322/.329
.331/.338
.338/.345
.347/.354
.357/.364
.367/.374
.376/.383
.385/.392
.396/.403
.403/.410
.412/.419
B
.286/.302
.291/.307
.298/.314
.312/.328
.319/.335
.328/.344
.335/.351
.344/.360
.354/.370
.364/.380
.373/.389
.382/.389
.393/.409
.400/.416
.409/.425
A (mm)
7.34/7.52
7.47/7.65
7.65/7.82
8.00/8.18
8.18/8.36
8.41/8.59
8.59/8.76
8.81/8.99
9.07/9.25
9.32/9.50
9.55/9.73
9.78/9.96
10.06/10.24
10.24/10.41
10.46/10.64
B (mm)
7.26/7.67
7.39/7.80
7.57/7.98
7.92/8.33
8.10/8.51
8.33/8.74
8.51/8.92
8.74/9.14
8.99/9.40
9.25/9.65
9.47/9.88
9.70/9.88
9.98/10.39
10.16/10.57
10.39/10.80
A & B Tolerances for Metric drilled holes

Note: For sizes not listed, use the A & B drill chart for tolerance.
mm
1.65
2.5
3.0
3.1
3.4
3.6
4.9
5.75
6.3
6.4
6.5
6.8
7.25
7.3
7.75
8.4
8.5
9.0
9.6
9.7
9.75
10
10.5
1.1
11.2
11.8
12
12.5
12.8
13
Inch)
A mm
A inch
B mm
B inch
.065
.098
.118
.122
.134
.142
.193
.226
.248
.252
.256
.268
.285
.287
.305
.331
.335
.354
.378
.382
.384
.394
.413
.433
.441
.465
.472
.492
.504
.512
1.62/1.78
2.46/2.61
2.97/3.12
3.07/3.22
3.38/3.53
3.58/3.73
4.87/5.03
5.71/5.87
6.27/6.42
6.37/6.55
6.47/6.65
6.78/6.96
7.21/7.39
7.26/7.44
7.72/7.90
8.38/8.56
8.48/8.66
8.96/9.14
9.57/9.75
9.67/9.85
9.72/9.90
9.98/10.16
10.46/10.64
10.97/11.15
11.17/11.35
11.78/11.96
11.96/12.14
12.47/12.65
12.75/13.00
12.95/13.20
.064/.070
.097/.103
.117/.123
.121/.127
.133/.139
.141/.147
.192/.198
.225/.231
.247/.253
.251/.258
.255/.262
.267/.274
.284/.291
.286/.293
.304/.311
.330/.337
.334/.341
.353/.360
377/.384
.381/.388
.383/.390
.393/.400
.412/.419
.432/.439
.440/.447
.464/.471
.471/.478
.491/.498
.502/.512
.510/.520
1.52/1.88
2.38/2.74
2.89/3.25
2.99/3.35
3.30/3.65
3.50/3.86
4.80/5.15
5.63/5.99
6.20/6.55
6.30/6.70
6.40/6.81
6.70/7.11
7.14/7.54
7.19/7.59
7.64/8.05
8.30/8.71
8.40/8.81
8.89/9.30
9.50/9.90
9.60/10.00
9.65/10.05
9.90/10.31
1.39/10.79
10.90/11.30
11.10/11.50
11.71/12.11
11.88/12.29
12.39/12.80
12.65/13.18
12.85/13.38
.060/.074
.094/.108
.114/.128
.118/.132
.130/.144
.138/.152
.189/.203
.222/.236
.244/.258
.248/.264
.252/.268
.264/.280
.281/.297
.283/.299
.301/.317
.327/.343
.331/.347
.350/.366
.374/.390
.378/.394
.380/.396
.390/.406
.409/.425
.429/.445
.437/.453
.461/.477
.468/.484
.488/.504
.498/.519
.506/.527

Page 10 of 34

A & B Tolerances for Metric drilled holes (Cont)
mm
13.5
13.6
14
14.35
14.4
14.5
14.75
16
16.5
17
17.35
17.5
17.75
18
18.5
19
19.5
20
20.5
21
21.5
22
22.5
23
23.5
24
24.5
25
Inch)
A mm
A inch
B mm
B inch
.532
.535
.551
.565
.567
.571
.581
.630
.650
.669
.683
.689
.699
.709
.728
.748
.768
.787
.807
.827
.846
.866
.884
.906
.925
.945
.965
.984
13.46/13.71
13.53/13.79
.13.94/14.20
14.30/14.55
14.35/14.60
14.45/14.70
14.70/14.96
15.95/16.20
16.46/16.71
16.94/17.19
17.29/17.55
17.45/17.70
17.70/17.96
17.96/18.21
18.44/18.69
18.95/19.20
19.45/19.76
19.94/20.24
20.44/20.75
20.95/21.26
21.43/21.74
21.94/22.25
22.45/22.76
22.96/23.26
23.44/23.75
23.95/24.25
24.46/24.76
24.94/25.24
.530/.540
.533/.543
.549/.559
.563/.573
.565/.575
.569/.579
.579/.589
.628/.638
.648/.658
.667/.677
.681/.691
.687/.697
.697/.707
.707/.717
.726/.736
.746/.756
.766/.778
.785/.797
.805/.817
.825/.837
.844/.856
.864/.876
.884/.896
.904/.916
.923/.935
.943/.955
.963/.975
.982/.994
13.36/13.89
13.43/13.97
13.84/14.37
14.20/14.73
14.25/14.78
14.35/14.88
14.60/15.14
15.85/16.38
16.35/16.89
16.84/17.37
17.19/17.73
17.35/17.88
17.60/.1714
17.85/18.39
18.34/18.87
18.84/19.38
19.35/20.01
19.84/20.50
20.34/21.00
20.85/21.51
21.33/22.00
21.84/22.50
22.35/23.01
22.86/23.52
23.34/24.00
23.85/24.51
24.35/25.02
24.84/25.50
.526/.547
.529/.550
.545/.566
.559/.580
.561/.582
.565/.586
.575/.596
.624/.645
.644/.665
.663/.684
.677/.698
.683/.704
.693/.714
.703/.724
.722/.743
.742/.763
.762/.788
.781/.807
.801/.827
.821/.847
.840/.866
.860/.886
.880/.906
.900/.926
.919/.945
.939/.965
.959/.985
.978/1.004

Page 11 of 34
A & B Tolerances for Numbered drilled holes

Hole Size
80
79
78
77
76
75
74
73
72
71
70
69
68
67
66
65
64
63
62
61
60
59
58
57
56
55
54
53
52
51
50
49
48
47
46
45
44
43
42
41
40
39
38
37
IN.
.013
.014
.016
.018
.020
.021
.022
.024
.025
.026
.028
.029
.031
.032
033
.035
.036
.037
.038
.039
.040
.041
.042
.043
.046
.052
.055
.060
.064
.067
.070
.073
.076
.078
.081
.082
.086
.089
.094
.096
.096
.100
.102
.104
A
.012/.016
.013/.017
.015/.019
.017/.021
.019/.023
.020/.024
.021/.025
.023/.027
.024/.028
.025/.029
.027/.031
.028/.032
.030/.034
.031/.035
.032/.036
.034/.038
.035/.039
.036/.040
.037/.041
.038/.042
.039/.043
.040/.044
.041/.045
.042/.046
.045/.049
.051/.055
.054/.058
.059/.063
.063/.069
.066/.072
.069/.075
.072/.078
.075/.081
.077/.083
.080/.086
.081/.087
.085/.091
.088/.094
.093/.099
.095/.101
.097/.103
.099/.105
.100/.107
.103/.109

B
.012/.016
.013/.017
.015/.019
.017/.021
.019/.023
.020/.024
.021/.025
.023/.027
.024/.028
.025/.029
.027/.031
.028/.032
.030/.034
.031/.035
.032/.036
.034/.038
.035/.039
.036/.040
.037/.041
.038/.042
.039/.043
.040/.044
.041/.045
.042/.046
.045/.049
051/.055
.054/.058
.059/.063
.060/.074
.063/.077
.066/.080
.069/.083
.072/.086
.074/.088
.077/.091
.078/.092
.082/.096
.085/.099
.090/.104
.092/.106
.094/.108
.096/.110
.098/.112
.100/.114
Page 12 of 34
A & B Tolerances for Number Drilled Holes Cont.

Hole Size
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
IN.
.106
.110
.111
.113
.116
.120
.128
.136
.140
.144
.147
.150
.152
.154
.157
.159
.161
.166
.170
.173
.177
.180
.182
.185
.189
.191
.194
.196
.199
.201
.204
.206
.209
.213
.221
.228
A
.105/.111
.109/.115
.110/.116
.112/.118
.115/.121
.119/.125
.127/.133
.135/.141
.139/.145
.143/.149
.146/.152
.149/.155
.151/.157
.153/.159
.156/.162
.158/.164
.160/.166
.165/.171
.169/.175
.172/.178
.176/.182
.179/.185
.181/.187
.184/.190
.188/.194
.190/.196
.193/.199
.195/.201
.198/.204
.200/.206
.203/.209
.205/.211
.208/.214
.212/.218
.220/.226
.227/.233

B
.102/.116
.106/.120
.107/.121
.109/.123
.112/.126
.116/.130
.124/.138
.132/.146
.136/.150
.140/.154
.143/.157
.146/.160
.148/.162
.150/.164
.153/.167
.155/.169
.157/.171
.162/.176
.166/.180
.169/.183
.173/.187
.176/.190
.178/.192
.181/.195
.185/.199
.187/.201
.190/.204
.192/.206
.195/.209
.197/.211
.200/.214
.202/.216
.205/.219
.209/.223
.217/.231
.224/.238
Page 13 of 34
Sandvik T-MAX U Drill bottom profile
T-MAX U Drill Diameter
Metric
18.50
to
20.99
3.50
3.00
0.60
0.80
21.00
to
25.99
4.00
3.50
0.70
0.80
26.00
to
30.99
5.10
4.60
0.90
0.80
31.00
to
41.99
6.10
5.60
1.10
0.80
42.00
to
56.00
8.10
7.40
1.40
1.20
0.728
to
0.826
0.138
0.118
0.024
0.032
0.827
to
1.023
0.158
0.138
0.028
0.032
1.024
to
1.220
0.2
0.181
0.035
0.032
1.220
to
1.653
0.24
0.22
0.043
0.032
1.654
to
2.205
0.319
0.291
0.055
0.047
Inch

Page 14 of 34
Fraction conversions
Fractional Inch to Decimal Inch and Millimeters
Fractional
Inch
1/64
Decimal
Inch
.0156
Millimeters
0.397
Fractional
Inch
33/64
Decimal
Inch
.5156
Millimeters
13.097
1/32
.0312
0.794
17/32
.5313
13.494
3/64
.0469
1.191
35/64
.5469
13.891
1/16
.0625
1.588
9/16
.5625
14.288
5/64
.0781
1.984
37/64
.5781
14.684
3/32
.0937
2.381
19/32
.5937
15.081
7/64
.1094
2.778
39/64
.6094
15.478
1/8
.125
3.175
5/8
.625
15.875
9/64
.1406
3.572
41/64
.6406
16.272
5/32
.1562
3.969
21/32
.6562
16.669
11/64
.1719
4.357
43/64
.6719
17.066
3/16
.1875
4.762
11/16
.6875
17.462
13/64
.2031
5.159
45/64
.7031
17.859
7/32
.2187
5.556
23/32
.7187
18.256
15/64
.2344
5.953
47/64
.7344
18.653
1/4
.25
6.350
3/4
.75
19.050
17/64
.2656
6.747
47/64
.7656
19.447
9/32
.2812
7.144
25/32
.7812
19.844
19/64
.2969
7.541
51/64
.7969
20.241
5/16
.3125
7.937
13/16
.8125
20.638
21/64
.3281
8.334
53/64
.8281
21.034
11/32
.3437
8.731
27/32
.8438
21.431
23/64
.3594
9.128
55/64
.8594
21.828
3/8
.375
9.525
7/8
.875
22.225
25/64
.3906
9.922
51/64
.8906
22.622
13/32
.4062
10.319
29/32
.9062
23.019
27/64
.4219
10.716
59/64
.9219
23.416
7/16
.4375
11.112
15/16
.9375
23.813
29/64
.4531
11.509
61/64
.9531
24.209
15/32
.4688
11.906
31/32
.9688
24.606
31/64
.4844
12.303
63/64
.9844
25.003
1/2
.50
12.700
1.0000
25.400
Note:
Metric dimension divided by 25.4 = Standard dimension
Standard dimension multiplied by 25.4 = Metric dimension

Page 15 of 34
Conversion Table
Millimeters to Inches
MM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Inches
0.03937
0.07874
0.11811
0.15748
0.19685
0.23622
0.27559
0.31496
0.35433
0.39370
0.43307
0.47244
0.51181
0.55118
0.59055
0.62992
0.66929
0.70866
0.74803
0.78740
0.82677
0.86614
0.90551
0.94480
0.98425
1.02362
1.06299
1.10236
1.14173
1.18110
1.22047
1.25984
1.29921
MM
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
Inches
1.33858
1.37795
1.41732
1.45669
1.49606
1.53543
1.57480
1.61417
1.65354
1.69291
1.73228
1.77165
1.81102
1.85039
1.88976
1.92913
1.96850
2.00787
2.04724
2.08661
2.12598
2.16535
2.20472
2.24409
2.28346
2.32283
2.36220
2.40157
2.44094
2.48031
2.51968
2.55905
2.59842
2.63779
MM
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
Inches
2.67716
2.71653
2.75590
2.79527
2.83464
2.87401
2.91338
2.95275
2.99212
3.03149
3.07086
3.11023
3.14960
3.18897
3.22834
3.26771
3.30708
3.34645
3.38582
3.42519
3.46456
3.50393
3.54330
3.58267
3.62204
3.66141
3.70078
3.74015
3.77952
3.81889
3.85826
3.89763
3.93700
Pressure Conversions P.S.I. to Metric

P.S.I. x 27.71 = .in H2O
P.S.I. x 2.036 = Hg
P.S.I. x 703.1 = mm/H2O
P.S.I. x 51.75 = mm/Hg
P.S.I. x .0703 = kg/cm2
Torque Conversions
Kg / m x 7.233 = ft/lbs
N/m x 8.9 = in/lbs
N/m x .74 = ft/lbs
1 Ft/lb = 12 in/lbs
P.S.I. x .0689 = bar

P.S.I. x 68.95 = mbar
P.S.I. x 6.895 = kPa
P.S.I. x 6895 = Pa
Approx. Wt. Conversion

Cast Iron = Steel x .91
Aluminum = Steel x .35
Delrin = Steel x .18
Brass = Steel x 1.08
Steel in lbs. = Area in cubic inch X .2836

Page 16 of 34
Hardness Conversion Tables for steel and hard alloys

C
Rockwell Scale
15N
30N
80
79
78
77
76
75
74
73
72
71
70
69
68
67
66
65
64
63
62
61
60
59
58
57
56
55
54
53
52
51
50
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
96.5
96.0
95.5
95.0
94.5
94.0
93.5
93.0
92.5
92.0
91.5
91.0
90.5
90.0
89.5
89.0
88.5
88.0
87.5
87.0
86.5
86.0
85.5
85.0
84.5
84.0
83.5
83.0
82.5
82.0
81.5
81.0
80.5
80.0
79.5
79.0
78.5
78.0
77.0
76.5
76.0
75.5
75.0
74.5
74.0
73.5
72.5
72.0
71.5
71.0
70.5
92.0
91.5
91.0
90.5
90.0
89.0
88.5
88.0
87.0
86.5
86.0
85.0
84.5
83.5
83.0
82.0
81.0
80.0
79.0
78.5
77.5
76.5
75.5
75.0
74.0
73.0
72.0
71.0
70.5
69.5
68.5
67.5
66.5
66.0
65.0
64.0
63.0
62.0
61.5
60.5
59.5
58.5
57.5
56.5
56.0
55.0
54.0
53.0
52.0
51.5
50.5
49.5
48.5
47.5
47.0
46.0
45.0
44.0
43.0
45N
Khn
500g & over
Bhn
3000 kg
87.0
86.5
85.5
84.5
83.5
82.5
81.5
80.5
79.5
78.5
77.5
76.5
75.5
74.5
73.0
72.0
71.0
70.0
69.0
67.5
66.5
65.5
64.0
63.0
62.0
61.0
59.5
58.5
57.5
56.0
55.0
54.0
52.5
51.5
50.0
49.0
48.0
46.5
45.5
44.5
43.0
42.0
41.0
39.5
38.5
37.0
36.0
35.0
33.5
32.5
31.5
30.0
29.0
28.0
26.5
25.5
24.0
23.0
22.0
972
946
920
895
870
846
822
799
776
754
732
710
690
670
650
630
612
594
576
558
542
526
510
495
480
466
452
438
426
414
402
391
380
370
360
351
342
334
326
318
311
304
297
290
284
278
272
266
261
614
600
587
573
560
547
534
522
509
496
484
472
460
448
437
426
415
404
393
382
372
362
352
342
332
322
313
305
297
290
283
276
270
265
260
255
250
245
240

Tensile Strength
1,000 psi
(approx.)
301
291
282
273
264
255
246
237
229
221
214
207
200
194
188
182
177
171
166
162
157
153
148
144
140
136
132
129
126
123
120
117
115
112
Page 17 of 34

C
Rockwell Scale
15N
30N
21
20
70.0
69.5
42.5
41.5
45N
Khn
500g & over
Bhn
3000 kg
20.5
19.5
256
251
235
230
Tensile Strength
1,000 psi
(approx.)
110
108
Rules for Hardness Testing for best results:

1. Remove all Decarburization.
2. Surface finish better 32 R.A.
3. Surface being tested must be perpendicular to the indentor.
Gauge and Wire Conversion - Decimals of an inch
Gauge NO.
2-0s
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
(For accuracy always specify by decimal)

Galvanized
Sheet
Steel Wire
MFRS.STD.*
Music Wire
Gage
Ga.**
.2391
.2243
.2092
.1943
.1793
.1644
.1495
.1345
.1196
.1046
.0897
.0747
.0673
.0598
.0538
.0478
.0418
.0359
.0329
.0299
.0269
.0239
.0209
.0179
.0164
.0149
.0135
.0120
.0105
.0097
.0090
.0082
.1681
.1532
.1382
.1233
.1084
.0934
.0785
.0710
.0635
.0575
.0516
.0456
.0396
.0366
.0336
.0306
.0276
.0247
.0217
.0202
.0187
.0172
.0157
.0142
.0134
-
.3310
.3065
.2830
.2625
.2437
.2253
.2070
.1920
.1770
.1620
.1483
.1350
.1205
.1055
.0915
.0800
.0720
.0625
.0540
.0475
.0410
.0348
.0317
.0286
.0258
.0230
.0204
.0181
.0173
.0162
.0150
.0140
.0132
.0128
.0118
.0104
.008
.009
.010
.011
.012
.013
.014
.016
.018
.020
.022
.024
.026
.029
.031
.033
.035
.037
.039
.041
.043
.045
.047
.049
.051
.055
.059
.063
.067
.071
.075
.080
.085
.090
.095
.100
Replaces U.S. Standard (Revised) Gauge

Replaces Washburn and Moen Gauge.

Page 18 of 34
Decimal Equivalents Conversions

For fractions, wire gauge, letter and metric sizes
Sizes
97
96
95
94
93
92
.2mm
91
90
.22mm
89
88
.25mm
87
86
85
.28mm
84
.3mm
83
82
.32mm
81
80
.35mm
79
1/64
.4mm
78
.45mm
77
.5mm
76
75
.55mm
74
.6mm
73
72
.65mm
71
.7mm
70
Decimal
0.0059
0.0063
0.0067
0.0071
0.0075
0.0079
0.0079
0.0083
0.0087
0.0087
0.0091
0.0095
0.0098
0.01
0.0105
0.011
0.011
0.0115
0.0118
0.012
0.0125
0.0126
0.013
0.0135
0.0138
0.0145
0.0156
0.0157
0.016
0.0177
0.018
0.0197
0.02
0.021
0.0217
0.0225
0.0236
0.024
0.025
0.0256
0.026
0.0276
0.028
Sizes
68
1/32
.8mm
67
66
.85mm
65
.9mm
64
63
.95mm
62
61
1mm
0.6
59
1.05mm
58
57
1.1mm
1.15mm
56
3/64
1.2mm
1.25mm
1.3mm
55
1.35mm
54
1.4mm
1.45mm
1.5mm
53
1.55mm
1/16
1.6mm
52
1.65mm
1.7mm
51
1.75mm
50
1.8mm
Decimal
0.031
0.0312
0.0315
0.032
0.033
0.0335
0.035
0.0354
0.036
0.037
0.0374
0.038
0.039
0.0394
0.04
0.041
0.0413
0.042
0.043
0.0433
0.0453
0.0465
0.0469
0.0472
0.0492
0.0512
0.052
0.0531
0.055
0.0551
0.0571
0.0591
0.0595
0.061
0.0625
0.063
0.0635
0.065
0.0669
0.067
0.0689
0.07
0.0709
Sizes
1.9mm
48
1.95mm
5/64
47
2mm
2.05mm
46
45
2.1mm
2.15mm
44
2.2mm
2.25mm
43
2.3mm
2.35mm
42
3/32
2.4mm
41
2.45mm
40
2.5mm
39
38
2.6mm
37
2.7mm
36
2.75mm
7/64
35
2.8mm
34
33
2.9mm
32
3mm
31
3.1mm
1/8
3.2mm
Decimal
0.0748
0.076
0.0768
0.0781
0.0785
0.0787
0.0807
0.081
0.082
0.0827
0.0846
0.086
0.0866
0.0886
0.089
0.0906
0.0925
0.0935
0.0938
0.0945
0.096
0.0965
0.098
0.0984
0.0995
0.1015
0.1024
0.104
0.1063
0.1065
0.1083
0.1094
0.11
0.1102
0.111
0.113
0.1142
0.116
0.1181
0.12
0.122
0.125
0.126

Sizes
3.3mm
3.4mm
29
3.5mm
28
9/64
3.6mm
27
3.7mm
26
3.75mm
25
3.8mm
24
3.9mm
23
5/32
22
4mm
21
20
4.1mm
4.2mm
19
4.25mm
4.3mm
18
11/64
17
4.4mm
16
4.5mm
15
4.6mm
14
13
4.7mm
4.75mm
3/16
4.8mm
12
11
4.9mm
Decimal
0.1299
0.1339
0.136
0.1378
0.1405
0.1406
0.1417
0.144
0.1457
0.147
0.1476
0.1495
0.1496
0.152
0.1535
0.154
0.1562
0.157
0.1575
0.159
0.161
0.1614
0.1654
0.166
0.1673
0.1693
0.1695
0.1719
0.173
0.1732
0.177
0.1772
0.18
0.1811
0.182
0.185
0.185
0.187
0.1875
0.189
0.189
0.191
0.1929
Page 19 of 34

Decimal Equivalents Conversions (Cont)
Sizes
69
.75mm
5mm
8
5.1mm
7
13/64
6
5.2mm
5
5.25mm
5.3mm
4
5.4mm
3
5.5mm
7/32
5.6mm
2
5.7mm
5.75mm
1
5.8mm
5.9mm
A
15/64
6mm
B
6.1mm
C
6.2mm
D
6.25mm
6.3mm
E
1/4
6.4mm
6.5mm
F
6.6mm
G
6.7mm
17/64
6.75mm
Decimal
0.0292
0.0295
0.1969
0.199
0.2008
0.201
0.2031
0.204
0.2047
0.2055
0.2067
0.2087
0.209
0.2126
0.213
0.2165
0.2188
0.2205
0.221
0.2244
0.2264
0.228
0.2283
0.2323
0.234
0.2344
0.2362
0.238
0.2402
0.242
0.2441
0.246
0.2461
0.248
0.25
0.25
0.252
0.2559
0.257
0.2598
0.261
0.2638
0.2656
0.2657
Sizes
1.85mm
49
7mm
J
7.1mm
K
9/32
7.2mm
7.25mm
7.3mm
L
7.4mm
M
7.5mm
19/64
7.6mm
N
7.7mm
7.75mm
7.8mm
7.9mm
5/16
8mm
O
8.1mm
8.2mm
P
8.25mm
8.3mm
21/64
8.4mm
Q
8.5mm
8.6mm
R
8.7mm
11/32
8.75mm
8.8mm
S
8.9mm
9mm
T
9.1mm
Decimal
0.0728
0.073
0.2756
0.277
0.2795
0.281
0.2812
0.2835
0.2854
0.2874
0.29
0.2913
0.295
0.2953
0.2969
0.2992
0.302
0.3031
0.3051
0.3071
0.311
0.3125
0.315
0.316
0.3189
0.3228
0.323
0.3248
0.3268
0.3281
0.3307
0.332
0.3346
0.3386
0.339
0.3425
0.3438
0.3445
0.3465
0.348
0.3504
0.3543
0.358
0.3583
Sizes
3.25mm
30
U
9.4mm
9.5mm
3/8
V
9.6mm
9.7mm
9.75mm
9.8mm
W
9.9mm
25/64
10mm
X
Y
13/32
Z
10.5mm
27/64
11mm
7/16
11.5mm
29/64
15/32
12mm
31/64
12.5mm
1/2
13mm
33/64
17/32
13.5mm
35/64
14mm
9/16
14.5mm
37/64
15mm
19/32
39/64
15.5mm
5/8
Decimal
0.128
0.1285
0.368
0.3701
0.374
0.375
0.377
0.378
0.3819
0.3839
0.3858
0.386
0.3898
0.3906
0.3937
0.397
0.404
0.4062
0.413
0.4134
0.4219
0.4331
0.4375
0.4528
0.4531
0.4688
0.4724
0.4844
0.4921
0.5
0.5118
0.5156
0.5312
0.5315
0.5469
0.5512
0.5625
0.5709
0.5781
0.5906
0.5938
0.6094
0.6102
0.625

Sizes
10
9
17mm
43/64
11/16
17.5mm
45/64
18mm
23/32
18.5mm
47/64
19mm
3/4
49/64
19.5mm
25/32
20mm
51/64
20.5mm
13/16
21mm
53/64
27/32
21.5mm
5564
22mm
7/8
22.5mm
57/64
23mm
29/32
59/64
23.5mm
15/16
24mm
61/64
24.5mm
31/32
25mm
63/64
1
Decimal
0.1935
0.196
0.6693
0.6719
0.6875
0.689
0.7031
0.7087
0.7188
0.7283
0.7344
0.748
0.75
0.7656
0.7677
0.7812
0.7874
0.7969
0.8071
0.8125
0.8268
0.8281
0.8438
0.8465
0.8594
0.8661
0.875
0.8858
0.8906
0.9055
0.9062
0.9219
0.9252
0.9375
0.9449
0.9531
0.9646
0.9688
0.9843
0.9844
1
Page 20 of 34

Decimal Equivalents Conversions (Cont)
Sizes
H
6.8mm
6.9mm
I
Decimal
0.266
0.2677
0.2717
0.272
Sizes
23/64
9.2mm
9.25mm
9.3mm
Decimal
0.3594
0.3622
0.3642
0.3661
Sizes
16mm
41/64
16.5mm
21/32
Decimal
0.6299
0.6409
0.6496
0.6562
Sizes
Decimal
SI - The Metrics International System of Units

The International System of Units (SI) is a modernized version of the metric system established by international
agreement. The metric system of measurement was developed during the French Revolution and was first promoted in
the U.S. by Thomas Jefferson. Its use was legalized in the U.S. in 1866. In 1902, proposed congressional legislation
requiring the U.S. Government to use the metric system exclusively was defeated by a single vote.
SI provides a logical and interconnected framework for all measurements in science, industry, and commerce. The metric
system is much simpler to use than the existing English system since all its units of measurement are divisible by 10.
Conversion Factors
The following list provides the conversion relationship between U.S. customary units and SI (International
System units. The proper conversion procedure is to multiply the specified value on the left (primarily U.S.
customary values) by the conversion factor exactly as given below and then round to the appropriate number
of significant digits desired. For example, to convert 11.4 ft to meters: 11.4 X 0.3048 = 3.47472, which rounds
to 3.47 meters. Do not round either value before performing the multiplication, as accuracy would be reduced.
A complete guide to the SI system and its use can be found in ASTM E 380, Metric Practice.
UNITS OF MEASURE As suggested by Federal Standard 376B
January 27, 1993
STANDARD ITEM TABLE
METRIC EQUIVALENT
ACRE
hectare (ha)
CUBIC FOOT
cubic meter (m3)
CUBIC YARD
cubic meter (m3)
FAHRENHEIT
kelvin (K) or degree Celsius (C)
FOOT/LBS
newton-meter (N-m)
FT. LBS./SEC.
watt (W)
GALLON/MGALLON
liter (L), cubic meter (m3)
HUNDRED WEIGHT
kilogram (kg)
INCH
millimeter (mm)
KIPS;KSI
kilopascal (kPa) or megapascal (MPa)
LBS/ACRE
kilograms/hectare
LBS/CU. FT.
kilogram per cubic meter (kg/m3)
LBS/SQ YD
kilopascal (kPa)
LBS/SQ. FT
kilopascal (kPa)
LBS/SQ. IN
kilopascal (kPa), megapascal (MPa if very large number)
LINEAR FOOT
meter (m)
MBOARD FEET
cubic meter (m3)
MIL
micrometer (um)
MILE
kilometer (km)
POUND
kilogram (kg) for mass, newton (N) for force
SQUARE FOOT
square meter (m2)
SQUARE YARD
square meter (m2)
TON
tonne (t)

Page 21 of 34
Length Conversion Factors

To convert from
mile (US Statute)
inch (in)
inch (in)
inch (in)
foot (ft)
yard (yd)
to
kilometer (km)
millimeter (mm)
centimeter (cm)
meter (m)
meter (m)
meter (m)
To convert from
square foot (sq ft)
square inch (sq in)
square yard (sq yd)
acre (ac)
to
square meter (sq m)
square meter (sq m)
square meter (sq m)
hectare (ha)
To convert from
cubic inch (cu in)
cubic foot (cu ft)
cubic yard (cu yd)
gallon (gal)
Canada liquid gallon (gal)
Canada liquid gallon (gal)
U.S. liquid** gallon (gal)
U.S. liquid,fluid ounce (fl oz)
U.S. liquid fluid ounce (fl oz)
to
cubic meter (cu m)
cubic meter (cu m)
cubic meter (cu m)
liter
cubic meter (cu m)
liter
cubic meter (cu m)
milliliters (ml)
cubic meter (cu m)
multiply by
1.609347
25.4 *
2.54 *
0.0254 *
0.3048 *
0.9144 *
Area Conversion Factors

multiply by
0.09290304 E
0.00064516 E
0.83612736 E
0.4047
Volume Conversion Factors

multiply by
0.00001639
0.02831685
0.7645549
4.546
0.004546
3.7854118
0.00378541
29.57353
0.00002957
**One U.S. gallon equals 0.8327 Canadian gallon.

Note: One U.S. gallon of water weighs 8.34 pounds (U.S.) at 60 degrees F.
One cubic foot of water weighs 62.4 pounds (U.S.).
One milliliter of water has a mass of 1 gram and has a volume of one cubic centimeter.
Force Conversion Factors

To convert from
kip (1000 lb)
kip (1000 lb)
pound (lb)
avoirdupois pound (lb)
to
kilogram (kg)
newton (N)
kilogram (kg)
newton (N)
multiply by
453.6
4,448.222
0.4535924
4.448222
Pressure or Stress Conversion Factors

To convert from
kip per square inch (ksi)
pound per square foot (psf)
pound per square foot (psf)
pound per square inch (psi)
pound per square inch (psi)
to
megapascal (MPa)
kilogram per square meter (kg/sq m)
pascal (Pa)
pascal (Pa)
megapascal (MPa)
multiply by
6.894757
4.8824
47.88
6,894.757
0.00689476
Mass (weight) Conversion Factors

To convert from
pound (lb)
avoirdupois ton, 2000 lb
to
kilogram (kg)
kilogram (kg)
multiply by
0.4535924
907.1848

Page 22 of 34

Mass (weight) per length
kip per linear foot (klf)
pound per linear foot (plf)
kilogram per meter (kg/m)

kilogram per meter (kg/m)
Mass per volume (density)

pound per cubic foot (pcf)
pound per cubic yard (lb/cu yd)
0.001488
1.488
kilogram per cubic meter (kg/cu m)

kilogram per cubic meter (kg/cu m)
16.01846
0.5933
Temperature Conversion Factors

To convert from
Temperature
degree Fahrenheit (F)
degree Fahrenheit (F)
kelvin (K)
Energy and heat
British thermal unit(Btu)
calorie (cal)
Btu/degree
kilowatt-hour (kwh)
British thermal unit per pound (Btu/lb)
British thermal unit per hour (Btu/hr)
to
multiply by
degree Celsius (C)

kelvin (K)
degree Celsius (C)
tc=(tF-32)/1.8
tk = (tF+459.7)/1.8
tc=tk-273.15
joule (J)
joule (J)
F x hr x ft2 W/m2 - degree K
joule (J)
calories per gram (cal/g)
watt (W)
1055.056
4.1868E
5.678263
3,600,000E
0.55556
0.2930711
Power Conversion Factors

Power
horsepower (hp)
watt (W)
745.6999 E
Velocity
mile per hour (mph)
mile per hour (mph)
kilometer per hour(km/hr)

meter per second (m/s)
1.60934
0.44704
Sheet Metal Conversion Factors

SHEET METAL Most specification references use gage number followed by the decimal inch thickness. Example: 22
gage (0.034 inch) Metric specifications use the absolute mm thickness. It is not the intent of this guidance to change the
thickness of currently used sheeting. The following chart may be used to specify sheet metal. The thickness under
"Specify" is thinner than the actual gage thickness, since specifications give minimum thickness.
Gage
Inch
Exact
(mm)
Specify
(mm)
32
30
28
26
24
22
20
18
16
14
12
10
8
0.0134
0.0157
0.0187
0.0217
0.0276
0.0336
0.0396
0.0516
0.0635
0.0785
0.1084
0.1382
0.1681
0.3404
0.3988
0.4750
0.5512
0.7010
0.8534
1.0058
1.3106
1.6129
1.9939
2.7534
3.5103
4.2697
0.34
0.39
0.47
0.55
0.70
0.85
1.0
1.3
1.6
1.9
2.7
3.5
4.2

Page 23 of 34
More Useful Conversion Factors

Quantity
From English
Units
To Metric
Units
Multiply
by*
Length
Mile
Yard
Foot
Inch
km
m
m
mm
1.609347
0.9144**
0.3048**
25.40**
square mile
Acre
Acre
square yard
square foot
square inch
km 2
m2
hectare
m2
m2
mm 2
2.590
4047
0.4047
0.8361
0.09290
645.2
acre foot
cubic yard
cubic foot
cubic foot
100 board feet
Gallon
m3
m3
m3
L (1000 cm 3)
m3
L (1000 cm 3)
1 233
0.7646
0.02832
28.32
0.2360
3.785
lb
kip (1000 lb)
kg
0.4536
metric ton (1000kg)
0.4536
plf
kg/m
1.488
psf
kg/m 2
4.882
pcf
kg/m 3
16.02
N
kN
4.448
4.448
N/m
kN/m
14.59
14.59
Pa
kPa
kPa
MPa
47.88
47.88
6.895
6.895
N.m
kN . m
1.356
1.356
Area
Volume
Mass
Mass/unit length
Mass/unit area
Mass density
Force
lb
Kip
Force/unit length
plf
Klf
Pressure, stress,
modules of elasticity
psf
ksf
psi
ksi
Bending moment,
torque, moment of force
ft-lb
ft-kip
* 4 significant digits
** denotes exact conversion

Page 24 of 34
Knurling
The term "Knurl" (Fine, Medium or Coarse) shall be interpreted as Diamond Knurl" unless otherwise
specified on the drawing. Note: When Diamond Knurl is called out, a Medium Knurl is preferred if size
is not specified.
Design Engineering should specify either a straight knurl or a diamond knurl (include class or size if
important) on the drawing.
If a straight knurl is shown on the drawing and called out as "Knurl", Design Engineering must be
called to verify which type of knurl is to be used and to update the drawing as required.
All Diameters are checked before knurling unless specified on the drawing.
Class, in TPI, should be specified by size, i.e. Coarse, Medium, Fine, or Extra Fine.
The following table represents a conversion of class to size:
Class
Coarse
Medium
Fine
Extra Fine
Teeth
Per
Inch
(Range)
16
25
35
50
12
20
30
40
Diametrical Pitch = Total number of teeth divided by the nominal tool diameter.
EXAMPLE: A knurling tool with a 64 D.P. and nominal diameter of .750.
64 X .750 = 48 Total number of teeth.
Total number of teeth divided by the circumference of tool (TTD) = Teeth Per Inch.
48 divided by (3.1416 X .750) = 20.37 T.P.I. which would be classified as Medium.
Optional Band Knurl


Page 25 of 34
Manufacturing Allowance for Holes
Reamed/Honed Hole Depth

Unless otherwise noted, all holes that are reamed or honed to final size must be controlled to the
specified size for a depth within 2.50mm (.100) max. of actual hole depth specified. I.e. Hole depth
is 12.70mm (.500), Reamed depth must be to 10.2mm (.400) min.
Press Fit Holes

Manufacturing of holes less than .05mm (.002) tolerance that are designed for a press application do
not require 100% clean-up. The following guidelines apply.
1. It must be determined that the application is a press fit and documented on the back of the routing on
where it is used.
2. The clean up is to be in tolerance and visually inspected to be no less than 50%.
3. The clean-up area must be cylindrical. No one side of the hole (entire Length), or max. hole depth of 25%
on one end. (bell-mouth)
4. Inspection is to be completed with bore gauge and final acceptance is to be plug gages.
5. Holes should not have a specified finish other than title block.
Unfinished area should not exceed .02% of the hole diameter, beyond maximum hole tolerance.
i.e. a 12.70/ 12.75mm (.500/.502) hole must not exceed 12.75mm (.502) + .02% or .25mm (.001)
= 12.75mm (.503) in the non cleaned up area.
Acceptance Standard for Thermally Cut Product

All products / blanks being thermally cut, i.e. laser, plasma, or flame cut need to meet the following
conditions and should be costed accordingly:
1) All slag to be removed from parts.
2) Cut surface not to exceed the profile tolerance or contain gouges exceeding 1/8 inch in depth, which
ever is better. This finish is not controlled by the title block surface finish but should be considered to
be a 1000A finish or better.
3) The starting / stopping point shall meet or be blended to meet the parts profile requirements specified
on the parts drawing.
Other part specific requirements not covered by the parts print are to be listed in the Item Data
Purchasing text.

Page 26 of 34

Purpose
This document describes the practices, guidelines, specifications and procedures necessary to assure quality forgings.
Scope
This document applies to all ferrous forgings performed at the Owatonna Eisenhower Drive facility using drop hammers
and upsetter.
Definitions and Acronyms

F.I.R. Full Indicator Reading
T.I.R. Total Indicator Reading
Documents, Forms and Equipment

The standard(s) listed below shall be considered a part of this specification where applicable. In the event of conflict, this
document shall take precedence unless otherwise indicated and specified.
PD0193 Manufacturing Standard Reference Guide
General Requirements
This shall apply to all Bosch end-use forgings, both Bosch worked and purchased. Steel forging suppliers shall meet
these requirements and shall have adequate means of material/process control, material testing, approvals, and reporting
to assure metallurgical quality of forging material and forged products.
In addition, forgings shall comply with supplementary and additional customer requirements not covered in this document.
Specifications and requirements shall be provided on drawings and/or purchase orders.
Forging Repairs
Salvage operations, such as repair welding, shall not be permitted unless approved by the manufacturing
engineer/metallurgist and/or specified on the drawing or work order. Repaired forgings shall be examined for acceptance
by the manufacturing engineer or metallurgist.
All repairs by welding shall conform to a Weld Procedure Sheet written by the supplier; this shall include: electrode,
welding parameters, method of removing defects, preheat/post-heat (if needed), finishing requirements, etc. The current
Weld Procedure Sheet shall be made available upon request for audit by Bosch.
Grain Size and Microstructure

Forging processes shall be controlled and monitored to ensure consistent microstructure, grain size, and surface
decarburization throughout the production history of the component. The forging process shall be validated whenever a
process change occurs.
Parts with more than 0.25% carbon that require machining or subsequent heat treatment (quench & temper) shall be
annealed or normalized after forging to soften the material, create homogeneity and relieve stresses from forging.
Verification of Flow Lines

New forgings shall be verified by macro etch examination that the flow line pattern is satisfactory to produce sound
forgings that are free of injurious defects such as interrupted flow lines, folds, laps, burrs, etc.
Existing forgings shall be re-verified by macro etch examination that the flow line pattern in any existing forging, which
undergoes a major change in part configuration, forging stock, die design, or forging process.

Page 27 of 34

Temperature Control
Unless otherwise specified, forging temperatures of various materials shall conform to commonly accepted industry
standards and should not exceed the recommended maximum hot working temperatures for the individual materials. Also
see Table 1 for general guideline.
Carbon
Content, %
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.90
1.00
Max. Safe Forging Temp.

Carbon Steels
Alloy Steels
C
F
C
F
1290
2350
1260
2300
1275
2325
1245
2275
1260
2300
1230
2250
1245
2275
1230
2250
1230
2250
1230
2250
1205
2200
1205
2200
1190
2175
1175
2150
1150
2100
1110
2025
-
Table 1 Maximum Safe Forging Temperature

For stock measuring up to 3.000 in diameter, the heating time per inch of section thickness should be no more than 5 min
for low-carbon and medium-carbon steels or no more than 6 min for low-allow steel. For stock 3.000 to 9.000 in
diameter, the heating time should be no more than 15 min per inch of thickness. For high-carbon steels (0.50% C and
higher) and for highly alloyed steel, slower heating rates are required to prevent cracking.
Parts should also be cooled according to manufacturers recommendations or as specified in order to avoid distortion,
injury and ensure complete transformation of austenite to pearlite and ferrite.
Finishing temperature should be well above the recrystallization temperature to prevent cracking. Recrystallization
temperature for steels is typically between 750F and 1300F.
Cleaning
Cleaning of forgings implies complete removal of hot rolling and forging scale that may interfere with subsequent
operations such as heat treating, machining, welding, painting, etc. Cleaning of forgings does not imply rust free, if the
forging is required to be rust free, this requirement shall be specified. Cleaning of the forging by the forger will aid critical
inspection and give assurance of a sound forging, free from injurious laps, seams, cracks, checks, and other surface
defects.
Methods for cleaning forgings may use any (but not limited to) the following processes: wheelabrating, sand blasting, shot
blasting, hydro-blasting, etc. Complete scale removal shall be obtained by the process used.
Inspection
Production forgings should be inspected once temperature reaches room temperature and should also be cleaned using
appropriate methods mentioned in Section 5.5 prior to inspection. Inspection of forgings shall meet all requirements and
specifications of Section 6.
Forging lap and fold shall not be permitted under any circumstances.
Forging cracks and bar seams shall not be permitted under any circumstances.
Underfills are not permissible beyond the allowances as defined in Section 6.
Gouges, dings, nicks, and other surface imperfections (except dress-outs) resulting from forging shall be
reworked/blended while remaining within specifications; otherwise, part is rejectable.

Page 28 of 34

General Specifications
This interprets drawing dimensions and tolerance requirements in addition to PD0193 for forging drawings and additional
requirements that shall be met unless otherwise specified on drawings or routing. This shall apply to all Bosch end-use
forgings, both Bosch worked and purchased. Steel forging suppliers shall meet these requirements to assure quality of
forged products.
General overall tolerance notes that may be specified in the title block of drawings do not apply to forging dimensions.
Length/Width/, Thickness, Radii and Die Wear Allowance

Unless specified, tolerance applies for all dimensions of length/width including diameter, radii and thickness as specified
in Table 2. This tolerance also includes allowance for die sinking, die polishing, die wear and shrinkage variations for all
dimensions.
Net Weight in
lbs.
0.2
0.4
0.6
0.8
1
2
3
4
5
10
20
30
40
inch
0.008
0.009
0.010
0.011
0.012
0.015
0.017
0.018
0.019
0.022
0.026
0.030
0.034
+
mm
0.20
0.22
0.25
0.28
0.30
0.38
0.43
0.45
0.48
0.55
0.66
0.75
0.86
inch
0.024
0.027
0.030
0.030
0.036
0.045
0.051
0.054
0.057
0.066
0.078
0.090
0.102
mm
0.60
0.68
0.75
0.75
0.91
1.14
1.29
1.37
1.44
1.67
1.98
2.28
2.59
Table 2 Commercial Forging Tolerances
Mismatch Allowance
This allowance relates to the displacement of a point in one die-half of the forging from a corresponding point in the
opposite die-half of the forging, in a direction parallel with the parting plane. Match allowance are applied separately and
independently to all other tolerances. Unless otherwise specified on the drawing or work instruction, match tolerances
shall apply on as-forged surfaces based on the following conditions:
a) Where machining is required, mismatch shall not exceed 50% of the machining allowance as indicated by the
difference between the forging dimensions and the machining dimensions.
b) Where machining is not required, mismatch shall not exceed the values specified in Figure 1.

Page 29 of 34

Mismatch Allowance
Weight in lbs
Over
Incl.
Tolerance, in
0.0
1.0
0.015
1.0
2.0
0.020
2.0
4.0
0.025
4.0
8.0
0.030
8.0
12.0
0.035
12.0
25.0
0.040
25.0
50.0
0.050
50.0
100.0
0.060
F.I.R or T.I.R or (A2 A1)/2 = M

Figure 1 Mismatch Allowance Based On
Forging Weight After Trimming
Allowances on Unforged Portion of Bars

Tolerances broader than commercial mill tolerances for bars are required for the unforged portion of the original bar within
the gripper area of upset forgings which retain the original bar as a portion of the forging. The gripper length varies from
forger to forger and the diameter tolerances listed in Figure 2 are required in the entire gripper length area of the bar on
the as-forged part. These tolerances are broad enough to cover the original mill tolerances on the bar. Tolerances in
Figure 2 apply to the entire unforged bar as well as the gripper area.
Nominal Bar
Size, in
0.000 to
2.000
2.000 to
4.500
4.500 to
5.500
5.500 to
6.500
Diameter
Tolerances, in
+0.060, -0.020
+0.090, -0.030
+0.120, -0.030
+0.150, -0.030
Figure 2 Tolerance For Gripper Diameter

And Original Bar Diameter

Page 30 of 34

Surface Condition Allowance
Surface tolerances relate to depth of dress-outs, scale pits, and other imperfections on the surface of forgings.
On surfaces to be machined, the material under a dress-out or scale pit shall meet the minimum machining allowance
specified on the machining drawing; it shall provide a minimum of 0.060 inches stock removal or 50% of the machining
allowance whichever is smaller.
On surfaces that are not to be machined, grinding out surface defects is permitted, provided the depression is minimal
and blended, and it does not cause that surface to fall outside of the limits specified on the forging drawing. Machining to
eliminate surface defects is allowed providing the defects are completely removed, and the machined surface is within
specifications. If the defect is not totally removed by these processes, or the surface falls outside of specifications, the part
is rejectable. See Figure 3 for surface allowance.
Area at the Trim Line

Flash not included, in^2
Over
Incl.
0
10
10
30
30
50
50
100
100
500
Tolerance, in
0.030
0.050
0.070
0.080
0.100
Figure 3 Surface Tolerances For Forgings

Intended For Use in As-Forged Condition
On forged surfaces that will not be machined, the surface finish should have a roughness equivalent to a surface finish of
500 RMS or finer.
Flash Allowance
Flash extension allowances for normal trim are additional to forging dimension tolerance. Tolerances on other than normal
trim (close trim, straight trim or pierce, or loose trim) are the same as the tolerances specified on the forging dimensions.
Normal trim applies to the bulk of forgings produced and is indicated on the forging dimensions portion of the part drawing
as illustrated in Figure 4. A trim dimension is not specified on the part drawing for normal trim. Due to piece part shift
during the trimming operation, flash extension may be a maximum on one side and completely removed on the opposite
side, resulting in a flat area. The size of the flat area is dependent upon the amount the forging shifts in the trim die, the
draft angle, and the thickness of the flash extension. Trimmer shift shall not exceed the maximum flash extension
allowance as shown in Figure 4, unless specified.

Page 31 of 34

Forging Weight, lbs.
(kg)
Over
Incl.
0
1/2
1
5
25
(0)
(0.2)
(0.5)
(2.3)
(11)
1/2
1
5
25
(0.2)
(0.5)
(2.3)
(11)
Maximum Flash Extension, in.

(mm)
0.02
(0.5)
0.025
(0.6)
0.03
(0.8)
0.06
(1.5)
0.09
(2.3)
Figure 4 Flash Extension Allowance For Normal Trim
Draft Angle Allowance

Draft angle tolerances apply to all draft angles, specified on drawings that are not affected by subsequent operations. See
Figure 5 for general guidelines.
Unless otherwise specified on the part drawing, the angular deviation allowable on the as-forged part from the draft
angle specified on the part drawing shall be +2, -1.
Type
Outside
Internal
Nominal
7
7 or 10
Commercial
0 to 7
0 to 13
Figure 5 General Draft Angle Tolerances
Straightness Allowance
Unless otherwise specified, straightness tolerance shall relate to deviations of surfaces and centerlines from the specified
contour and are applied independently of, and in addition to, all other tolerances.
Straightness allowance is divided into four general classes of shapes and shall be used accordingly to determine the
appropriate straightness tolerances:
Class A An Elongated Length dimension greater than width or height (ex: pry bars, jaws, wrenches, jimmy bars, puller
bars, etc.)
Class B Flat and thin (ex: discs, plates, etc.)
Class C Flat and thin with protrusion at right angles to the parting line
Class D Block-type forgings with neither length, width nor thickness being predominant (ex: splitter blocks, c-frames,
eye bolts, heads, etc.)
For Class A shapes, allowance shall be 0.003 inches per inch of the greatest dimension rounded up to the nearest 0.010
inches.
For Class B shapes, see Figure 6.

Page 32 of 34

Area at the Trim Line
Flash not included, in^2
Over
Incl.
0
10
10
30
30
50
50
100
500
1000
Tolerance, in
0.030
0.060
0.090
0.120
0.150
Figure 6 Class B Tolerances

For Class C, flat portion shall be determined using Figure 7. Protruding portion shall be 0.003 inches per inch
perpendicular from the parting line.
For Class D shapes, where tolerances are desired, they shall be specified in the routings and/or work instructions.
Deviations and Waivers

Any deviations or waivers with regards to the use of this standard shall be forwarded to Quality or Engineering for review
and approval.

Page 33 of 34

Instructions for setting a Bite Type ferrule. Ref Drawing 516398.

Page 34 of 34

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General Manufacturing Tolerances

. 01 mm per 5 linear mm (.002 per linear inch)

Perpendicularly, Angularity & Chamfers:

Untoleranced fractional dimensions will be inspected per the following:

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Manufacturing Standards for Blend

Borroughs Manufacturing Standards

Standard Hole Tolerances and Surface Finish Standards

Print Date: August 31, 2016

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External Chamfer on Threads

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Chamfer on Squares, Hexagons & Octagons

Countersink on a curved surface

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Countersinks on Internal Straight Threads

NOMINAL THREAD DIA.

Recommended External Thread Relief

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A & B Drill Tolerance Table

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All Dimensions except size designation are in inches.

A & B Tolerances for Fraction and Letter drilled holes

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A & B Tolerances for Metric drilled holes

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A & B Tolerances for Numbered drilled holes

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