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

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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 . 01 mm per 5 linear mm (.002 per linear inch)
Rough Cutting . 1 mm per 10 linear mm (.010 per linear inch)
Perpendicularly, Angularity & Chamfers:
Machined (with specified RMS on the chamfer or angle) ± 2
Machined (w/o specified RMS on the chamfer or angle) ± 5
Rough (hand belting, c/r, on the chamfer or angle) ± 10
Welding ± 2
Rough cutting (saw, flamecut, Laser etc.) ± 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: Untoleranced fractional dimensions will be inspected per the following:
1. Saw +/- .75mm (.032)
2. Punch +/- .38mm (.015) (Also See Sheared Edge Specification)
3. All Other +/- .38mm (.015)
4. Weldment +/- 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”).

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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 ± .75mm (± .030)
One Place Decimal ± 1.50mm (± .060)
Two Place Decimal ± .75mm (± .030)
Three Place Decimal ± .25mm (± .010)
Angles ± 5
Corner Breaks .05mm / .50mm (.002 /.020)
Surface Finish 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:
CASE HARDEN .25mm (.010) MIN. EFFECTIVE DEPTH.
To specify for High Wear Resistance and High Load note as:
CASE HARDEN .75mm (.030) MIN. EFFECTIVE DEPTH.

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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 A = mm A = inches Threads A = mm A = inches
Per Inch +.5mm - .000 +.020 -.000 Per Inch +.5mm - .000 +.020 -.000
4 4.2 .165 13 1.5 .060
4½ 3.7 .145 14 1.4 .055
5 3.4 .135 16 1.3 .050
6 2.9 .115 18 1.1 .045
7 2.5 .100 20 1.0 .040
8 2.3 .090 24 .90 .035
9 2.0 .080 28 .75 .030
10 1.8 .070 32 .75 .030
11 1.6 .065 36 .65 .027
12 1.5 .060 40 .60 .025

Metric
Metric Thread A = mm A = inches Metric Thread A = mm A = inches
Pitch +.5mm - .000 +.020 -.000 Pitch +.5mm - .000 +.020 -.000
.35 .4 .015 1.75 1.3 .050
.4 .4 .015 2 1.5 .060
.45 .5 .020 2.5 1.8 .070
.5 .5 .020 3 2.1 .080
.6 .5 .020 3.5 2.4 .095
.7 .6 .025 4 2.7 .105
.75 .6 .025 4.5 3.0 .120
.8 .6 .025 5 3.3 .130
1 .8 .030 5.5 3.6 .140
1.25 1.0 .040 6 3.9 .155
1.5 1.1 .043

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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 A

LESS THAN 13mm (.500”) .75mm (.030)
13mm – 25mm (.500”-1.000”) 1.50mm (.060)
OVER 25mm (1.000”) 2.25mm (.090)

Countersink on a curved surface

NOTE: Chamfer must meet minor diameter on short side and can go over on long.

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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. “A” + to +

0 – <6mm (0 - .249)
6mm - <13mm (.250 - .499)
13mm - <22mm (.500 - .874)
22mm - <32mm (.875 - 1.250)
Larger than 32mm (1.250)
.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

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A & B Drill Tolerance Table

(Refer to A & B tolerance charts on the following pages)
DRILL DIA. A
B
+.08mm -.02mm +.08mm - .02mm
Thru. 1.50mm (.062)
(+.003 -.001) (+.003 -.001)
Over 1.50mm (.062) +.12mm - .02mm +.25mm - .10mm
Thru. 6.3mm (.250) (+.005 -.001) (+.010 -.004)
Over 6.3mm (.250) +.15mm - .02mm +.30mm - .10mm
Thru. 12.7mm (.500) (+.006 -.001) (+.012 -.004)
Over 12.7mm (.500) +.20mm - .05mm +.38mm - .15mm
Thru. 19.0mm (.750) (+.008 -.002) (+.015 -.006)
Over 19.0mm (.750) +.25mm - .05mm +.50mm - .15mm
Thru. 25.4mm (1.000) (+.010 -.002) (+.020 -.006)
+.25mm - .075mm +.50mm - .25mm
Over 25.4mm (1.000)
(+.010 -.003) (+.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 Drill Drill Overall Body Drill Drill Overall Bell

Diam. Diam. Length Length Size Diam. Diam. Length Length Diam.
Size
A D C L A D C L E
1/8 3/64 3/64 1 1/4 1/8 3/64 3/64 1 1/4 0.100
1 11
3.17mm 1.19mm 1.19mm 31.75mm 3.17mm 1.19mm 1.19mm 31.75mm 2.54mm
3/16 5/64 5/64 1 7/8 3/16 5/64 5/64 1 7/8 0.150
2 12
4.75mm 1.98mm 1.98mm 47.62mm 4.75mm 1.98mm 1.98mm 47.62mm 3.81mm

Body Drill Drill Overall Body Drill Drill Overall Bell

Diam. Diam. Length Length Size Diam. Diam. Length Length Diam.
Size
1/4 7/64 7/64 2 1/4 7/64 7/64 2 0.200
3 13
6.35mm 2.78mm 2.78mm 50.8mm 6.35mm 2.78mm 2.78mm 50.8mm 5.08mm
5/16 1/8 1/8 2 1/8 5/16 1/8 1/8 2 1/8 0.250
4 14
7.92mm 3.17mm 3.17mm 53.97mm 7.92mm 3.17mm 3.17mm 53.97mm 6.35mm
7/16 3/16 3/16 2 3/4 7/16 3/16 3/16 2 3/4 0.350
5 15
11.10mm 4.75mm 4.75mm 69.85mm 11.10mm 4.75mm 4.75mm 69.85mm 8.89mm
1/2 7/32 7/32 3 1/2 7/32 7/32 3 0.400
6 16
12.7mm 5.55mm 5.55mm 76.20mm 12.7mm 5.55mm 5.55mm 76.20mm 10.16mm

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5/8 1/4 1/4 3 1/4 5/8 1/4 1/4 3 1/4 0.500
7 17
15.87mm 6.35mm 6.35mm 82.55mm 15.87mm 6.35mm 6.35mm 82.55mm 12.70mm
3/4 5/16 5/16 3 1/2 3/4 5/16 5/16 3 1/2 0.600
8 18
19.05mm 7.92mm 7.92mm 88.90mm 19.05mm 7.92mm 7.92mm 88.90mm 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 Decimal A B A (mm) B (mm)

1/64 0.016 .015/.019 .015/.019 0.38/0.48 0.38/0.48
1/32 0.031 .030/.034 .030/.034 0.76/0.86 0.76/0.86
3/64 0.047 .046/.050 .046/.050 1.17/1.27 1.17/1.27
1/16 0.062 .061/.065 .061/.065 1.55/1.65 1.55/1.65
5/64 0.078 .077/.083 .074/.088 1.96/2.11 1.88/2.24
3/32 0.094 .093/.099 .090/.104 2.36/2.51 2.29/2.64
7/64 0.109 .108/.114 .105/.119 2.74/2.90 2.67/3.02
1/8 0.125 .124.130 .121/.136 3.15/3.30 3.07/3.45
9/64 0.141 .140/.146 .137/.151 3.56/3.71 3.48/3.84
5/32 0.156 .155/.161 .152/.166 3.94/4.09 3.86/4.22
11/64 0.172 .171/.177 .168/.182 4.34/4.50 4.27/4.62
3/16 0.188 .187/.193 .184/.198 4.75/4.90 4.67/5.03
13/64 0.203 .202/.208 .199/.213 5.13/5.28 5.05/5.41
7/32 0.219 .218/.224 .215/.229 5.54/5.69 5.46/5.82
15/64 0.234 .233/.239 .230/.244 5.92/6.07 5.84/6.20
1/4 0.250 .249/.255 .246/.260 6.32/6.48 6.25/6.60
17/64 0.266 .265/.272 .262/.278 6.73/6.91 6.65/7.06
9/32 0.281 .280/.287 .277/.293 7.11/7.29 7.04/7.44
19/64 0.297 .296/.303 .293/.309 7.52/7.70 7.44/7.85
5/16 0.312 .311/.318 .308/.324 7.90/8.08 7.82/8.23
21/64 0.328 .327/.334 .324/.340 8.31/8.48 8.23/8.64
11/32 0.344 .343/.350 .340/.356 8.71/8.89 8.64/9.04
23/64 0.359 .358/.365 .355/.371 9.09/9.27 9.02/9.42
3/8 0.375 .374/.381 .371/.387 9.50/9.68 9.42/9.83
25/64 0.391 .390/.397 .387/.403 9.91/10.08 9.83/10.24

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

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

A & B Tolerances for Metric drilled holes

Rounded off to 3 Decimal Places per ANSI Standard Z25.1
Note: For sizes not listed, use the A & B drill chart for tolerance.
mm Inch) A mm A inch B mm B inch
1.65 .065 1.62/1.78 .064/.070 1.52/1.88 .060/.074
2.5 .098 2.46/2.61 .097/.103 2.38/2.74 .094/.108
3.0 .118 2.97/3.12 .117/.123 2.89/3.25 .114/.128
3.1 .122 3.07/3.22 .121/.127 2.99/3.35 .118/.132
3.4 .134 3.38/3.53 .133/.139 3.30/3.65 .130/.144
3.6 .142 3.58/3.73 .141/.147 3.50/3.86 .138/.152
4.9 .193 4.87/5.03 .192/.198 4.80/5.15 .189/.203
5.75 .226 5.71/5.87 .225/.231 5.63/5.99 .222/.236
6.3 .248 6.27/6.42 .247/.253 6.20/6.55 .244/.258
6.4 .252 6.37/6.55 .251/.258 6.30/6.70 .248/.264
6.5 .256 6.47/6.65 .255/.262 6.40/6.81 .252/.268
6.8 .268 6.78/6.96 .267/.274 6.70/7.11 .264/.280
7.25 .285 7.21/7.39 .284/.291 7.14/7.54 .281/.297
7.3 .287 7.26/7.44 .286/.293 7.19/7.59 .283/.299
7.75 .305 7.72/7.90 .304/.311 7.64/8.05 .301/.317
8.4 .331 8.38/8.56 .330/.337 8.30/8.71 .327/.343
8.5 .335 8.48/8.66 .334/.341 8.40/8.81 .331/.347
9.0 .354 8.96/9.14 .353/.360 8.89/9.30 .350/.366
9.6 .378 9.57/9.75 377/.384 9.50/9.90 .374/.390
9.7 .382 9.67/9.85 .381/.388 9.60/10.00 .378/.394
9.75 .384 9.72/9.90 .383/.390 9.65/10.05 .380/.396
10 .394 9.98/10.16 .393/.400 9.90/10.31 .390/.406
10.5 .413 10.46/10.64 .412/.419 1.39/10.79 .409/.425
1.1 .433 10.97/11.15 .432/.439 10.90/11.30 .429/.445
11.2 .441 11.17/11.35 .440/.447 11.10/11.50 .437/.453
11.8 .465 11.78/11.96 .464/.471 11.71/12.11 .461/.477
12 .472 11.96/12.14 .471/.478 11.88/12.29 .468/.484
12.5 .492 12.47/12.65 .491/.498 12.39/12.80 .488/.504
12.8 .504 12.75/13.00 .502/.512 12.65/13.18 .498/.519
13 .512 12.95/13.20 .510/.520 12.85/13.38 .506/.527

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A & B Tolerances for Metric drilled holes (Con’t)
mm Inch) A mm A inch B mm B inch
13.5 .532 13.46/13.71 .530/.540 13.36/13.89 .526/.547
13.6 .535 13.53/13.79 .533/.543 13.43/13.97 .529/.550
14 .551 .13.94/14.20 .549/.559 13.84/14.37 .545/.566
14.35 .565 14.30/14.55 .563/.573 14.20/14.73 .559/.580
14.4 .567 14.35/14.60 .565/.575 14.25/14.78 .561/.582
14.5 .571 14.45/14.70 .569/.579 14.35/14.88 .565/.586
14.75 .581 14.70/14.96 .579/.589 14.60/15.14 .575/.596
16 .630 15.95/16.20 .628/.638 15.85/16.38 .624/.645
16.5 .650 16.46/16.71 .648/.658 16.35/16.89 .644/.665
17 .669 16.94/17.19 .667/.677 16.84/17.37 .663/.684
17.35 .683 17.29/17.55 .681/.691 17.19/17.73 .677/.698
17.5 .689 17.45/17.70 .687/.697 17.35/17.88 .683/.704
17.75 .699 17.70/17.96 .697/.707 17.60/.1714 .693/.714
18 .709 17.96/18.21 .707/.717 17.85/18.39 .703/.724
18.5 .728 18.44/18.69 .726/.736 18.34/18.87 .722/.743
19 .748 18.95/19.20 .746/.756 18.84/19.38 .742/.763
19.5 .768 19.45/19.76 .766/.778 19.35/20.01 .762/.788
20 .787 19.94/20.24 .785/.797 19.84/20.50 .781/.807
20.5 .807 20.44/20.75 .805/.817 20.34/21.00 .801/.827
21 .827 20.95/21.26 .825/.837 20.85/21.51 .821/.847
21.5 .846 21.43/21.74 .844/.856 21.33/22.00 .840/.866
22 .866 21.94/22.25 .864/.876 21.84/22.50 .860/.886
22.5 .884 22.45/22.76 .884/.896 22.35/23.01 .880/.906
23 .906 22.96/23.26 .904/.916 22.86/23.52 .900/.926
23.5 .925 23.44/23.75 .923/.935 23.34/24.00 .919/.945
24 .945 23.95/24.25 .943/.955 23.85/24.51 .939/.965
24.5 .965 24.46/24.76 .963/.975 24.35/25.02 .959/.985
25 .984 24.94/25.24 .982/.994 24.84/25.50 .978/1.004

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A & B Tolerances for Numbered drilled holes

Rounded off to 3 Decimal Places per ANSI Standard Z25.1

Hole Size IN. A B

80 .013 .012/.016 .012/.016
79 .014 .013/.017 .013/.017
78 .016 .015/.019 .015/.019
77 .018 .017/.021 .017/.021
76 .020 .019/.023 .019/.023
75 .021 .020/.024 .020/.024
74 .022 .021/.025 .021/.025
73 .024 .023/.027 .023/.027
72 .025 .024/.028 .024/.028
71 .026 .025/.029 .025/.029
70 .028 .027/.031 .027/.031
69 .029 .028/.032 .028/.032
68 .031 .030/.034 .030/.034
67 .032 .031/.035 .031/.035
66 033 .032/.036 .032/.036
65 .035 .034/.038 .034/.038
64 .036 .035/.039 .035/.039
63 .037 .036/.040 .036/.040
62 .038 .037/.041 .037/.041
61 .039 .038/.042 .038/.042
60 .040 .039/.043 .039/.043
59 .041 .040/.044 .040/.044
58 .042 .041/.045 .041/.045
57 .043 .042/.046 .042/.046
56 .046 .045/.049 .045/.049
55 .052 .051/.055 051/.055
54 .055 .054/.058 .054/.058
53 .060 .059/.063 .059/.063
52 .064 .063/.069 .060/.074
51 .067 .066/.072 .063/.077
50 .070 .069/.075 .066/.080
49 .073 .072/.078 .069/.083
48 .076 .075/.081 .072/.086
47 .078 .077/.083 .074/.088
46 .081 .080/.086 .077/.091
45 .082 .081/.087 .078/.092
44 .086 .085/.091 .082/.096
43 .089 .088/.094 .085/.099
42 .094 .093/.099 .090/.104
41 .096 .095/.101 .092/.106
40 .096 .097/.103 .094/.108
39 .100 .099/.105 .096/.110
38 .102 .100/.107 .098/.112
37 .104 .103/.109 .100/.114

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A & B Tolerances for Number Drilled Holes Cont.
Rounded off to 3 Decimal Places per ANSI Standard Z25.1

Hole Size IN. A B

36 .106 .105/.111 .102/.116
35 .110 .109/.115 .106/.120
34 .111 .110/.116 .107/.121
33 .113 .112/.118 .109/.123
32 .116 .115/.121 .112/.126
31 .120 .119/.125 .116/.130
30 .128 .127/.133 .124/.138
29 .136 .135/.141 .132/.146
28 .140 .139/.145 .136/.150
27 .144 .143/.149 .140/.154
26 .147 .146/.152 .143/.157
25 .150 .149/.155 .146/.160
24 .152 .151/.157 .148/.162
23 .154 .153/.159 .150/.164
22 .157 .156/.162 .153/.167
21 .159 .158/.164 .155/.169
20 .161 .160/.166 .157/.171
19 .166 .165/.171 .162/.176
18 .170 .169/.175 .166/.180
17 .173 .172/.178 .169/.183
16 .177 .176/.182 .173/.187
15 .180 .179/.185 .176/.190
14 .182 .181/.187 .178/.192
13 .185 .184/.190 .181/.195
12 .189 .188/.194 .185/.199
11 .191 .190/.196 .187/.201
10 .194 .193/.199 .190/.204
9 .196 .195/.201 .192/.206
8 .199 .198/.204 .195/.209
7 .201 .200/.206 .197/.211
6 .204 .203/.209 .200/.214
5 .206 .205/.211 .202/.216
4 .209 .208/.214 .205/.219
3 .213 .212/.218 .209/.223
2 .221 .220/.226 .217/.231
1 .228 .227/.233 .224/.238

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Sandvik T-MAX U Drill bottom profile

T-MAX U Drill Diameter A B C R

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
Inch
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

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Fraction conversions
Fractional Inch to Decimal Inch and Millimeters
Fractional Decimal Fractional Decimal
Inch Inch Millimeters Inch Inch Millimeters
1/64 .0156 0.397 33/64 .5156 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 1.0000 25.400

Note:
Metric dimension divided by 25.4 = Standard dimension
Standard dimension multiplied by 25.4 = Metric dimension
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Conversion Table
Millimeters to Inches
MM Inches MM Inches MM Inches
1 0.03937 34 1.33858 68 2.67716
2 0.07874 35 1.37795 69 2.71653
3 0.11811 36 1.41732 70 2.75590
4 0.15748 37 1.45669 71 2.79527
5 0.19685 38 1.49606 72 2.83464
6 0.23622 39 1.53543 73 2.87401
7 0.27559 40 1.57480 74 2.91338
8 0.31496 41 1.61417 75 2.95275
9 0.35433 42 1.65354 76 2.99212
10 0.39370 43 1.69291 77 3.03149
11 0.43307 44 1.73228 78 3.07086
12 0.47244 45 1.77165 79 3.11023
13 0.51181 46 1.81102 80 3.14960
14 0.55118 47 1.85039 81 3.18897
15 0.59055 48 1.88976 82 3.22834
16 0.62992 49 1.92913 83 3.26771
17 0.66929 50 1.96850 84 3.30708
18 0.70866 51 2.00787 85 3.34645
19 0.74803 52 2.04724 86 3.38582
20 0.78740 53 2.08661 87 3.42519
21 0.82677 54 2.12598 88 3.46456
22 0.86614 55 2.16535 89 3.50393
23 0.90551 56 2.20472 90 3.54330
24 0.94480 57 2.24409 91 3.58267
25 0.98425 58 2.28346 92 3.62204
26 1.02362 59 2.32283 93 3.66141
27 1.06299 60 2.36220 94 3.70078
28 1.10236 61 2.40157 95 3.74015
29 1.14173 62 2.44094 96 3.77952
30 1.18110 63 2.48031 97 3.81889
31 1.22047 64 2.51968 98 3.85826
32 1.25984 65 2.55905 99 3.89763
33 1.29921 66 2.59842 100 3.93700
67 2.63779

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
Print Date: August 31, 2016
QMS electronic document is the controlled copy
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
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Hardness Conversion Tables for steel and hard alloys
Rockwell Scale Khn Bhn Tensile Strength
C 15N 30N 45N 500g & over 3000 kg 1,000 psi
(approx.)
80 96.5 92.0 87.0 - - -
79 - 91.5 86.5 - - -
78 96.0 91.0 85.5 - - -
77 - 90.5 84.5 - - -
76 95.5 90.0 83.5 - - -
75 - 89.0 82.5 - - -
74 95.0 88.5 81.5 - - -
73 - 88.0 80.5 - - -
72 94.5 87.0 79.5 - - -
71 - 86.5 78.5 - - -
70 94.0 86.0 77.5 972 - -
69 93.5 85.0 76.5 946 - -
68 - 84.5 75.5 920 - -
67 93.0 83.5 74.5 895 - -
66 92.5 83.0 73.0 870 - -
65 92.0 82.0 72.0 846 - -
64 - 81.0 71.0 822 - -
63 91.5 80.0 70.0 799 - -
62 91.0 79.0 69.0 776 - -
61 90.5 78.5 67.5 754 - -
60 90.0 77.5 66.5 732 614 -
59 89.5 76.5 65.5 710 600 -
58 - 75.5 64.0 690 587 -
57 89.0 75.0 63.0 670 573 -
56 88.5 74.0 62.0 650 560 -
55 88.0 73.0 61.0 630 547 301
54 87.5 72.0 59.5 612 534 291
53 87.0 71.0 58.5 594 522 282
52 86.5 70.5 57.5 576 509 273
51 86.0 69.5 56.0 558 496 264
50 85.5 68.5 55.0 542 484 255
49 85.0 67.5 54.0 526 472 246
48 84.5 66.5 52.5 510 460 237
47 84.0 66.0 51.5 495 448 229
46 83.5 65.0 50.0 480 437 221
45 83.0 64.0 49.0 466 426 214
44 82.5 63.0 48.0 452 415 207
43 82.0 62.0 46.5 438 404 200
42 81.5 61.5 45.5 426 393 194
41 81.0 60.5 44.5 414 382 188
40 80.5 59.5 43.0 402 372 182
39 80.0 58.5 42.0 391 362 177
38 79.5 57.5 41.0 380 352 171
37 79.0 56.5 39.5 370 342 166
36 78.5 56.0 38.5 360 332 162
35 78.0 55.0 37.0 351 322 157
34 77.0 54.0 36.0 342 313 153
33 76.5 53.0 35.0 334 305 148
32 76.0 52.0 33.5 326 297 144
31 75.5 51.5 32.5 318 290 140
30 75.0 50.5 31.5 311 283 136
29 74.5 49.5 30.0 304 276 132
28 74.0 48.5 29.0 297 270 129
27 73.5 47.5 28.0 290 265 126
26 72.5 47.0 26.5 284 260 123
25 72.0 46.0 25.5 278 255 120
24 71.5 45.0 24.0 272 250 117
23 71.0 44.0 23.0 266 245 115
22 70.5 43.0 22.0 261 240 112

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

(For accuracy always specify by decimal)
Galvanized
Sheet Steel Wire
Gauge NO. MFRS.STD.* Gage Ga.** Music Wire
2-0’s - - .3310 .008
0 - - .3065 .009
1 - - .2830 .010
2 - - .2625 .011
3 .2391 - .2437 .012
4 .2243 - .2253 .013
5 .2092 - .2070 .014
6 .1943 - .1920 .016
7 .1793 - .1770 .018
8 .1644 .1681 .1620 .020
9 .1495 .1532 .1483 .022
10 .1345 .1382 .1350 .024
11 .1196 .1233 .1205 .026
12 .1046 .1084 .1055 .029
13 .0897 .0934 .0915 .031
14 .0747 .0785 .0800 .033
15 .0673 .0710 .0720 .035
16 .0598 .0635 .0625 .037
17 .0538 .0575 .0540 .039
18 .0478 .0516 .0475 .041
19 .0418 .0456 .0410 .043
20 .0359 .0396 .0348 .045
21 .0329 .0366 .0317 .047
22 .0299 .0336 .0286 .049
23 .0269 .0306 .0258 .051
24 .0239 .0276 .0230 .055
25 .0209 .0247 .0204 .059
26 .0179 .0217 .0181 .063
27 .0164 .0202 .0173 .067
28 .0149 .0187 .0162 .071
29 .0135 .0172 .0150 .075
30 .0120 .0157 .0140 .080
31 .0105 .0142 .0132 .085
32 .0097 .0134 .0128 .090
33 .0090 - .0118 .095
34 .0082 - .0104 .100
Replaces U.S. Standard (Revised) Gauge
Replaces Washburn and Moen Gauge.

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Decimal Equivalents Conversions
For fractions, wire gauge, letter and metric sizes
Sizes Decimal Sizes Decimal Sizes Decimal Sizes Decimal
97 0.0059 68 0.031 1.9mm 0.0748 3.3mm 0.1299
96 0.0063 1/32 0.0312 48 0.076 3.4mm 0.1339
95 0.0067 .8mm 0.0315 1.95mm 0.0768 29 0.136
94 0.0071 67 0.032 5/64 0.0781 3.5mm 0.1378
93 0.0075 66 0.033 47 0.0785 28 0.1405
92 0.0079 .85mm 0.0335 2mm 0.0787 9/64 0.1406
.2mm 0.0079 65 0.035 2.05mm 0.0807 3.6mm 0.1417
91 0.0083 .9mm 0.0354 46 0.081 27 0.144
90 0.0087 64 0.036 45 0.082 3.7mm 0.1457
.22mm 0.0087 63 0.037 2.1mm 0.0827 26 0.147
89 0.0091 .95mm 0.0374 2.15mm 0.0846 3.75mm 0.1476
88 0.0095 62 0.038 44 0.086 25 0.1495
.25mm 0.0098 61 0.039 2.2mm 0.0866 3.8mm 0.1496
87 0.01 1mm 0.0394 2.25mm 0.0886 24 0.152
86 0.0105 0.6 0.04 43 0.089 3.9mm 0.1535
85 0.011 59 0.041 2.3mm 0.0906 23 0.154
.28mm 0.011 1.05mm 0.0413 2.35mm 0.0925 5/32 0.1562
84 0.0115 58 0.042 42 0.0935 22 0.157
.3mm 0.0118 57 0.043 3/32 0.0938 4mm 0.1575
83 0.012 1.1mm 0.0433 2.4mm 0.0945 21 0.159
82 0.0125 1.15mm 0.0453 41 0.096 20 0.161
.32mm 0.0126 56 0.0465 2.45mm 0.0965 4.1mm 0.1614
81 0.013 3/64 0.0469 40 0.098 4.2mm 0.1654
80 0.0135 1.2mm 0.0472 2.5mm 0.0984 19 0.166
.35mm 0.0138 1.25mm 0.0492 39 0.0995 4.25mm 0.1673
79 0.0145 1.3mm 0.0512 38 0.1015 4.3mm 0.1693
1/64 0.0156 55 0.052 2.6mm 0.1024 18 0.1695
.4mm 0.0157 1.35mm 0.0531 37 0.104 11/64 0.1719
78 0.016 54 0.055 2.7mm 0.1063 17 0.173
.45mm 0.0177 1.4mm 0.0551 36 0.1065 4.4mm 0.1732
77 0.018 1.45mm 0.0571 2.75mm 0.1083 16 0.177
.5mm 0.0197 1.5mm 0.0591 7/64 0.1094 4.5mm 0.1772
76 0.02 53 0.0595 35 0.11 15 0.18
75 0.021 1.55mm 0.061 2.8mm 0.1102 4.6mm 0.1811
.55mm 0.0217 1/16 0.0625 34 0.111 14 0.182
74 0.0225 1.6mm 0.063 33 0.113 13 0.185
.6mm 0.0236 52 0.0635 2.9mm 0.1142 4.7mm 0.185
73 0.024 1.65mm 0.065 32 0.116 4.75mm 0.187
72 0.025 1.7mm 0.0669 3mm 0.1181 3/16 0.1875
.65mm 0.0256 51 0.067 31 0.12 4.8mm 0.189
71 0.026 1.75mm 0.0689 3.1mm 0.122 12 0.189
.7mm 0.0276 50 0.07 1/8 0.125 11 0.191
70 0.028 1.8mm 0.0709 3.2mm 0.126 4.9mm 0.1929

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Decimal Equivalents Conversions (Con’t)
Sizes Decimal Sizes Decimal Sizes Decimal Sizes Decimal
69 0.0292 1.85mm 0.0728 3.25mm 0.128 10 0.1935
.75mm 0.0295 49 0.073 30 0.1285 9 0.196
5mm 0.1969 7mm 0.2756 U 0.368 17mm 0.6693
8 0.199 J 0.277 9.4mm 0.3701 43/64 0.6719
5.1mm 0.2008 7.1mm 0.2795 9.5mm 0.374 11/16 0.6875
7 0.201 K 0.281 3/8 0.375 17.5mm 0.689
13/64 0.2031 9/32 0.2812 V 0.377 45/64 0.7031
6 0.204 7.2mm 0.2835 9.6mm 0.378 18mm 0.7087
5.2mm 0.2047 7.25mm 0.2854 9.7mm 0.3819 23/32 0.7188
5 0.2055 7.3mm 0.2874 9.75mm 0.3839 18.5mm 0.7283
5.25mm 0.2067 L 0.29 9.8mm 0.3858 47/64 0.7344
5.3mm 0.2087 7.4mm 0.2913 W 0.386 19mm 0.748
4 0.209 M 0.295 9.9mm 0.3898 3/4 0.75
5.4mm 0.2126 7.5mm 0.2953 25/64 0.3906 49/64 0.7656
3 0.213 19/64 0.2969 10mm 0.3937 19.5mm 0.7677
5.5mm 0.2165 7.6mm 0.2992 X 0.397 25/32 0.7812
7/32 0.2188 N 0.302 Y 0.404 20mm 0.7874
5.6mm 0.2205 7.7mm 0.3031 13/32 0.4062 51/64 0.7969
2 0.221 7.75mm 0.3051 Z 0.413 20.5mm 0.8071
5.7mm 0.2244 7.8mm 0.3071 10.5mm 0.4134 13/16 0.8125
5.75mm 0.2264 7.9mm 0.311 27/64 0.4219 21mm 0.8268
1 0.228 5/16 0.3125 11mm 0.4331 53/64 0.8281
5.8mm 0.2283 8mm 0.315 7/16 0.4375 27/32 0.8438
5.9mm 0.2323 O 0.316 11.5mm 0.4528 21.5mm 0.8465
A 0.234 8.1mm 0.3189 29/64 0.4531 5564 0.8594
15/64 0.2344 8.2mm 0.3228 15/32 0.4688 22mm 0.8661
6mm 0.2362 P 0.323 12mm 0.4724 7/8 0.875
B 0.238 8.25mm 0.3248 31/64 0.4844 22.5mm 0.8858
6.1mm 0.2402 8.3mm 0.3268 12.5mm 0.4921 57/64 0.8906
C 0.242 21/64 0.3281 1/2 0.5 23mm 0.9055
6.2mm 0.2441 8.4mm 0.3307 13mm 0.5118 29/32 0.9062
D 0.246 Q 0.332 33/64 0.5156 59/64 0.9219
6.25mm 0.2461 8.5mm 0.3346 17/32 0.5312 23.5mm 0.9252
6.3mm 0.248 8.6mm 0.3386 13.5mm 0.5315 15/16 0.9375
E 0.25 R 0.339 35/64 0.5469 24mm 0.9449
1/4 0.25 8.7mm 0.3425 14mm 0.5512 61/64 0.9531
6.4mm 0.252 11/32 0.3438 9/16 0.5625 24.5mm 0.9646
6.5mm 0.2559 8.75mm 0.3445 14.5mm 0.5709 31/32 0.9688
F 0.257 8.8mm 0.3465 37/64 0.5781 25mm 0.9843
6.6mm 0.2598 S 0.348 15mm 0.5906 63/64 0.9844
G 0.261 8.9mm 0.3504 19/32 0.5938 1 1
6.7mm 0.2638 9mm 0.3543 39/64 0.6094
17/64 0.2656 T 0.358 15.5mm 0.6102
6.75mm 0.2657 9.1mm 0.3583 5/8 0.625

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Decimal Equivalents Conversions (Con’t)
Sizes Decimal Sizes Decimal Sizes Decimal Sizes Decimal
H 0.266 23/64 0.3594 16mm 0.6299
6.8mm 0.2677 9.2mm 0.3622 41/64 0.6409
6.9mm 0.2717 9.25mm 0.3642 16.5mm 0.6496
I 0.272 9.3mm 0.3661 21/32 0.6562

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)

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Length Conversion Factors

To convert from to multiply by
mile (US Statute) kilometer (km) 1.609347
inch (in) millimeter (mm) 25.4 *
inch (in) centimeter (cm) 2.54 *
inch (in) meter (m) 0.0254 *
foot (ft) meter (m) 0.3048 *
yard (yd) meter (m) 0.9144 *

Area Conversion Factors

To convert from to multiply by
square foot (sq ft) square meter (sq m) 0.09290304 E
square inch (sq in) square meter (sq m) 0.00064516 E
square yard (sq yd) square meter (sq m) 0.83612736 E
acre (ac) hectare (ha) 0.4047

Volume Conversion Factors

To convert from to multiply by
cubic inch (cu in) cubic meter (cu m) 0.00001639
cubic foot (cu ft) cubic meter (cu m) 0.02831685
cubic yard (cu yd) cubic meter (cu m) 0.7645549
gallon (gal) liter 4.546
Canada liquid gallon (gal) cubic meter (cu m) 0.004546
Canada liquid gallon (gal) liter 3.7854118
U.S. liquid** gallon (gal) cubic meter (cu m) 0.00378541
U.S. liquid,fluid ounce (fl oz) milliliters (ml) 29.57353
U.S. liquid fluid ounce (fl oz) cubic meter (cu m) 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 to multiply by
kip (1000 lb) kilogram (kg) 453.6
kip (1000 lb) newton (N) 4,448.222
pound (lb) kilogram (kg) 0.4535924
avoirdupois pound (lb) newton (N) 4.448222

Pressure or Stress Conversion Factors

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

Mass (weight) Conversion Factors

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

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Mass (weight) per length

kip per linear foot (klf) kilogram per meter (kg/m) 0.001488
pound per linear foot (plf) kilogram per meter (kg/m) 1.488

Mass per volume (density)

pound per cubic foot (pcf) kilogram per cubic meter (kg/cu m) 16.01846
pound per cubic yard (lb/cu yd) kilogram per cubic meter (kg/cu m) 0.5933

Temperature Conversion Factors

To convert from to multiply by
Temperature
degree Fahrenheit (F) degree Celsius (C) tc=(tF-32)/1.8
degree Fahrenheit (F) kelvin (K) tk = (tF+459.7)/1.8
kelvin (K) degree Celsius (C) tc=tk-273.15
Energy and heat
British thermal unit(Btu) joule (J) 1055.056
calorie (cal) joule (J) 4.1868E
Btu/degree F x hr x ft2 W/m2 - degree K 5.678263
kilowatt-hour (kwh) joule (J) 3,600,000E
British thermal unit per pound (Btu/lb) calories per gram (cal/g) 0.55556
British thermal unit per hour (Btu/hr) watt (W) 0.2930711

Power Conversion Factors

Power
horsepower (hp) watt (W) 745.6999 E

Velocity
mile per hour (mph) kilometer per hour(km/hr) 1.60934
mile per hour (mph) meter per second (m/s) 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 Specify

(mm) (mm)

32 0.0134 0.3404 0.34

30 0.0157 0.3988 0.39
28 0.0187 0.4750 0.47
26 0.0217 0.5512 0.55
24 0.0276 0.7010 0.70
22 0.0336 0.8534 0.85
20 0.0396 1.0058 1.0
18 0.0516 1.3106 1.3
16 0.0635 1.6129 1.6
14 0.0785 1.9939 1.9
12 0.1084 2.7534 2.7
10 0.1382 3.5103 3.5
8 0.1681 4.2697 4.2

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More Useful Conversion Factors

Quantity From English To Metric Multiply
Units Units by*
Length
Mile km 1.609347
Yard m 0.9144**
Foot m 0.3048**
Inch mm 25.40**
Area
square mile km 2 2.590
Acre m2 4047
Acre hectare 0.4047
square yard m2 0.8361
square foot m2 0.09290
square inch mm 2 645.2
Volume
acre foot m3 1 233
cubic yard m3 0.7646
cubic foot m3 0.02832
cubic foot L (1000 cm 3) 28.32
100 board feet m3 0.2360
Gallon L (1000 cm 3) 3.785
Mass
lb kg 0.4536
kip (1000 lb) metric ton (1000kg) 0.4536
Mass/unit length
plf kg/m 1.488
Mass/unit area
psf kg/m 2 4.882
Mass density
pcf kg/m 3 16.02
Force
lb N 4.448
Kip kN 4.448
Force/unit length
plf N/m 14.59
Klf kN/m 14.59
Pressure, stress,
modules of elasticity
psf Pa 47.88
ksf kPa 47.88
psi kPa 6.895
ksi MPa 6.895
Bending moment,
torque, moment of force
ft-lb N.m 1.356
ft-kip kN . m 1.356
* 4 significant digits
** denotes exact conversion
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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 16 25 35 50
Per
Inch
(Range) 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

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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 part‘s profile requirements specified
on the part’s drawing.
Other part specific requirements not covered by the part’s print are to be listed in the Item Data
Purchasing text.

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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.

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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.

Max. Safe Forging Temp.

Carbon Carbon Steels Alloy Steels
Content, % °C °F °C °F
0.10 1290 2350 1260 2300
0.20 1275 2325 1245 2275
0.30 1260 2300 1230 2250
0.40 1245 2275 1230 2250
0.50 1230 2250 1230 2250
0.60 1205 2200 1205 2200
0.70 1190 2175 1175 2150
0.90 1150 2100 - -
1.00 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 manufacturer’s 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 750°F and 1300°F.

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.

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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.
inch mm inch mm
0.2 0.008 0.20 0.024 0.60
0.4 0.009 0.22 0.027 0.68
0.6 0.010 0.25 0.030 0.75
0.8 0.011 0.28 0.030 0.75
1 0.012 0.30 0.036 0.91
2 0.015 0.38 0.045 1.14
3 0.017 0.43 0.051 1.29
4 0.018 0.45 0.054 1.37
5 0.019 0.48 0.057 1.44
10 0.022 0.55 0.066 1.67
20 0.026 0.66 0.078 1.98
30 0.030 0.75 0.090 2.28
40 0.034 0.86 0.102 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.

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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 Diameter

Size, in Tolerances, in
0.000 to +0.060, -0.020
2.000
2.000 to +0.090, -0.030
4.500
4.500 to +0.120, -0.030
5.500
5.500 to +0.150, -0.030
6.500
Figure 2 – Tolerance For Gripper Diameter
And Original Bar Diameter

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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. Tolerance, in
0 10 0.030
10 30 0.050
30 50 0.070
50 100 0.080
100 500 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.

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Forging Weight, lbs.

(kg)
Over Incl. Maximum Flash Extension, in.
(mm)
0 (0) 1/2 (0.2) 0.02 (0.5)
1/2 (0.2) 1 (0.5) 0.025 (0.6)
1 (0.5) 5 (2.3) 0.03 (0.8)
5 (2.3) 25 (11) 0.06 (1.5)
25 (11) 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 Nominal Commercial

Outside 7 0 to 7
Internal 7 or 10 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.

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Area at the Trim Line

Flash not included, in^2
Over Incl. Tolerance, in
0 10 0.030
10 30 0.060
30 50 0.090
50 100 0.120
500 1000 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.

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

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