Tool Info

Thread Mill Cutting Diameter 0.08 *Note: When choosing a tool, make sure that bot
Thread Milll Flat Length ("Crest") 0.0008
Neck Diameter of Thread Mill 0.04 *IMPORTANT: If you are using a multi-tooth thre
Tooth Height of Thread Mill 0.04

INTERNAL Common Thread Size Calculations

Thread Size Drill Size Decimal Final PDO Tool Check
4-40 UNC #43 0.089 0.0262 Good
6-32 UNC #36 0.1065 0.0364 Good
8-32 UNC #29 0.136 0.0322 Good
10-24 UNC #25 0.1495 0.0472 Wrong Tool
10-32 UNF #21 0.159 0.0358 Good
1/4-20 UNC #7 0.201 0.0574 Wrong Tool
1/4-28 UNF #3 0.213 0.0430 Wrong Tool
5/16-18 UNC F 0.257 0.0652 Wrong Tool
5/16-24 UNF I 0.272 0.0472 Wrong Tool
3/8-16 UNC 5/16" 0.3125 0.0736 Wrong Tool
3/8-24 UNF Q 0.332 0.0502 Wrong Tool
7/16-14 UNC U 0.368 0.0820 Wrong Tool
7/16-20 UNF W 0.386 0.0604 Wrong Tool
1/2-13 UNC 27/64" 0.4219 0.0924 Wrong Tool
1/2-20 UNF 29/64" 0.4531 0.0549 Wrong Tool

EXTERNAL Common Thread Size Calculations

Thread Size Major Dia. Final PDO Tool Check
4-40 UNC 0.01965 0.0368 Good
6-32 UNC 0.1342 0.0465 Wrong Tool
8-32 UNC 0.1601 0.0465 Wrong Tool
10-24 UNC 0.1854 0.0630 Wrong Tool
10-32 UNF 0.1861 0.0465 Wrong Tool
1/4-20 UNC 0.2428 0.0734 Wrong Tool
1/4-28 UNF 0.2441 0.0514 Wrong Tool
5/16-18 UNC 0.3048 0.0820 Wrong Tool
5/16-24 UNF 0.3060 0.0605 Wrong Tool
3/8-16 UNC 0.3666 0.0930 Wrong Tool
3/8-24 UNF 0.3685 0.0605 Wrong Tool
7/16-14 UNC 0.4284 0.1068 Wrong Tool
7/16-20 UNF 0.4301 0.0734 Wrong Tool
1/2-13 UNC 0.4904 0.1154 Wrong Tool
1/2-20 UNF 0.4926 0.0734 Wrong Tool
oosing a tool, make sure that both the tool diameter fits in your drilled hole and the tooth height is deeper than your PDO

you are using a multi-tooth thread mill, set this to 0. This value is unnecessary as long as you are cutting a TPI that is specific to your too
is deeper than your PDO

are cutting a TPI that is specific to your tool.

SAUNDERS MACHINE WORKS / NYC CNC THREAD MILL CALCULATOR
Blue = Input

Internal Threadmilling; Hole Modeled as MINOR Diameter

*all dimensions in inches

1 Inputs
Major Diameter
Minor Diameter (e.g. drill diameter)
0.5
0.465

Threadmill Tool Information

2
Thread Mill Cutting Diameter 0.388
Thread Milll Flat Length ("Crest") 0.003

Pitch Diameter Offset

3
Pitch Diameter Offset (Minor) 0.0368

Pitch Diameter Offset (Major) 0.0018

CALCULATOR

*Note: When choosing a tool, make sure that both the tool diameter fits in you

Check Mfg's website. A.k.a. Crest

If CAD has minor (e.g. 0.201" for a 1/4x20)

If CAD has major (e.g. 0.25" for a 1/4x20)

at both the tool diameter fits in your drilled hole and the tooth height is deeper than your PDO
SAUNDERS MACHINE WORKS / NYC CNC THREAD MILL CALCULATOR
Blue = Input

Internal Threadmilling; Hole Modeled as MINOR Diameter

*all dimensions in inches
Inputs

1
Major Diameter 0.375
Thread Class 2B
Minimum Minor Diameter 0.3125
Maximum Minor Diameter 0.3125
Source: Machinery's Handbook 30th Edition P. 1869-1895

Threadmill Tool Information

Thread Mill Cutting Diameter 0.188

2
Thread Milll Flat Length ("Crest") 0.003
Height Missing from Thread Mill 0.00260
Neck Diameter of Thread Mill 0.12
Tooth Height of Thread Mill 0.068

Pitch Diameter Offset

Average Minor Diameter 0.3125

3
1) Pitch Diameter Offset (P.D.O.) 0.0625
2) Adjust P.D.O. Out 0.0125
3) Adjust P.D.O. In -0.0052
Pitch Diameter Offset (Minor) 0.0698

Pitch Diameter Offset (Major) 0.0073

Explanation of calculations
Pitch Diameter Offset is the difference between your Major and Minor thread diameters. However, because the threa
this theoretical Major Diameter, in order to cut deeper. To do this, we expand the Major diameter by 2 times the Adju
After expanding the Major Diameter, we shrink it to compensate for the small amount that the tool is actually flat-tippe
This will give you your final Pitch Diameter Offset, but keep in mind that there is a tolerance window for the diameter v

Equation
Pitch Diameter Offset = [(Theoretical Major Diameter)+(2*AdjustmentAmount)-(2*Height Missing from Thread Mill Pea

Thread Tolerance Calculations

Minimum Thread Tolerance
 Minimum Minor Diameter 0.3125
Actual Thread Height 0.03125
Theoretical Triangle Height 0.05
Adjustment Amount 0.00625

*Machinery's Handbook 30th Edition Pages 1859-1860

Thread Profile Graphic

Notice the tool (in green, bue, and red) does not cut the whole thread profile whe
CALCULATOR

Only Informational; does not affect calculations

Put same value in each field (Min and Max) if
using ONE minor diameter - e.g. Tap Drill Dia.
d

*Note: When choosing a tool, make sure that both the tool diameter
Tool Check
If your final PDO is greater than your tool's Tooth Height, it will break
Check Mfg's website. A.k.a. Crest the tool trying to push it into the thread wall.

*IMPORTANT: If you are using a multi-tooth thread mill,

set this to 0.This value is unnecessary as long as you are
cutting a TPI that is specific to your tool. Wrong Tool

Calculations use AVERAGE Minor Diameter; this NEEDS to be the CAD diameter

Standard offset assuming thread mill was perfectly sized and shaped for this TPI
Assumes Thread Mill flutes came to a sharp point
Adjusts for estimated flat tip of threadmill tool
If CAD has minor (e.g. 0.201" for a 1/4x20)

If CAD has major (e.g. 0.25" for a 1/4x20)

d Minor thread diameters. However, because the thread mill tool comes to a near perfect point, we have to expand
this, we expand the Major diameter by 2 times the Adjustment Amount (1 for each side of the thread,
te for the small amount that the tool is actually flat-tipped. This final equation to determine your Pitch Diameter Offset is posted below.
mind that there is a tolerance window for the diameter values.

ustmentAmount)-(2*Height Missing from Thread Mill Peak)]-Minor Diameter

Average Thread Tolerance Maximum Thread Tolerance

 Average Minor Diameter 0.3125 Maximum Minor Diameter
Actual Thread Height (aka 1/2 P.D.O) 0.03125 Actual Thread Height
Theoretical Triangle Height (If Thread Came to Sharp Point)
0.05 Theoretical Triangle Height
Adjustment Amount to push tool out 0.00625 Adjustment Amount

, and red) does not cut the whole thread profile when only pushed out to the Theoretical PDO. Instead, we have to make adjustme
ake sure that both the tool diameter fits in your drilled hole and the tooth height is deeper than your PDO

our tool's Tooth Height, it will break

Wrong Tool

e to expand

ameter Offset is posted below.

Maximum Thread Tolerance

 0.3125
0.03125
0.05
0.00625

stead, we have to make adjustments to the PDO so that the walls of the tool line up with the walls of the thread.
er than your PDO
p with the walls of the thread.
SAUNDERS MACHINE WORKS / NYC CNC THREAD MILL CALCULATOR
Blue = Input

External Threadmilling; Hole Modeled as MAJOR Diameter

1
*all dimensions in inches
Inputs
Minor Diameter 0.1394
Major Diameter 0.1854

Threadmill Tool Information

2
Thread Mill Cutting Diameter 0.24
Thread Milll Flat Length ("Crest") 0.0024
Height Missing from Thread Mill 0.00208

Pitch Diameter Offset

Average Minor Diameter 0.1394

1) Pitch Diameter Offset (P.D.O.) 0.046

2) Adjust P.D.O. Out 0.0184
3) Adjust P.D.O. In -0.0042

3
Pitch Diameter Offset 0.0602

Thread Tolerance Calculations

Minimum Thread Tolerance
Minimum Major Diameter 0.1854
Actual Thread Height -0.023
Theoretical Triangle Height -0.0368
Adjustment Amount -0.0092
LCULATOR

*Note: When choosing a tool, make sure that both the tool diameter fits in you
Check Mfg's website, A.k.a. Crest

Calculations use AVERAGE Minor Diameter

Standard offset assuming thread mill was perfectly sized and shaped for this TPI
Assumes Thread Mill flutes came to a sharp point
Adjusts for *estimated* flat tip of threadmill tool

Average Thread Tolerance Maximum Thread Tolerance

Average Major Diameter 0.1854 Maximum Major Diameter
Actual Thread Height (aka 1/2 P.D.O) 0.023 Actual Thread Height
Theoretical Triangle Height (If Thread Came to Sharp Point)
0.0368 Theoretical Triangle Height
Adjustment Amount to push tool out 0.0092 Adjustment Amount
at both the tool diameter fits in your drilled hole and the tooth height is deeper than your PDO

Maximum Thread Tolerance

0.1854
-0.023
-0.0368
-0.0092
SAUNDERS MACHINE WORKS / NYC CNC THREAD MILL CALCULATOR
Blue = Input

External Threadmilling; Hole Modeled as MAJOR Diameter

*all dimensions in inches
Inputs

1
Minor Diameter 0.4069
Thread Class 2B
Minimum Major Diameter 0.4985
Maximum Major Diameter 0.4822
Source: Machinery's Handbook 30th Edition P. 1869-1895

Threadmill Tool Information

Thread Mill Cutting Diameter 0.388

2
Thread Milll Flat Length ("Crest") 0.0035
Height Missing from Thread Mill 0.00303
Neck Diameter of Thread Mill 0
Tooth Height of Thread Mill 0.388

Pitch Diameter Offset

Average Major Diameter 0.49035

3
1) Pitch Diameter Offset (P.D.O.) 0.08345
2) Adjust P.D.O. Out 0.03338
3) Adjust P.D.O. In -0.0061
Pitch Diameter Offset 0.1108

Explanation of calculations
Pitch Diameter Offset is the difference between your Major and Minor thread diameters. However, because the threa
this theoretical Major Diameter, in order to cut deeper. To do this, we expand the Major diameter by 2 times the Adju
After expanding the Major Diameter, we shrink it to compensate for the small amount that the tool is actually flat-tippe
This will give you your final Pitch Diameter Offset, but keep in mind that there is a tolerance window for the diameter v

Equation
Pitch Diameter Offset = [(Theoretical Major Diameter)+(2*AdjustmentAmount)-(2*Height Missing from Thread Mill Pea

Thread Tolerance Calculations

Minimum Thread Tolerance
 Minimum Major Diameter 0.4985
Actual Thread Height -0.0458
Theoretical Triangle Height -0.07328
Adjustment Amount -0.01832
*Machinery's Handbook 30th Edition Pages 1859-1860

Thread Profile Graphic

Notice the tool (in green, bue, and red) does not cut the whole thread profile when only pushed out to the The
CALCULATOR

Only Informational; does not affect calculations

Put same value in each field (Min and Max) if
using ONE major diameter - e.g. Tap Drill Dia.
d

*Note: When choosing a tool, make sure that both the tool diameter
Tool Check
If your final PDO is greater than your tool's Tooth Height, it will break
Check Mfg's website. A.k.a. Crest the tool trying to push it into the thread wall.

*IMPORTANT: If you are using a multi-tooth thread mill,

set this to 0.This value is unnecessary as long as you are
cutting a TPI that is specific to your tool. Good

Calculations use AVERAGE Major Diameter; this NEEDS to be the CAD diameter

Standard offset assuming thread mill was perfectly sized and shaped for this TPI
Assumes Thread Mill flutes came to a sharp point
Adjusts for estimated flat tip of threadmill tool d

d Minor thread diameters. However, because the thread mill tool comes to a near perfect point, we have to expand
this, we expand the Major diameter by 2 times the Adjustment Amount (1 for each side of the thread,
te for the small amount that the tool is actually flat-tipped. This final equation to determine your Pitch Diameter Offset is posted below.
mind that there is a tolerance window for the diameter values.

stmentAmount)-(2*Height Missing from Thread Mill Peak)]-Minor Diameter

Average Thread Tolerance Maximum Thread Tolerance

 Average Major Diameter 0.49035 Maximum Major Diameter
Actual Thread Height (aka 1/2 P.D.O) 0.041725 Actual Thread Height
Theoretical Triangle Height (If Thread Came to Sharp Point)
0.06676 Theoretical Triangle Height
Adjustment Amount to push tool out 0.01669 Adjustment Amount

hole thread profile when only pushed out to the Theoretical PDO. Instead, we have to make adjustments to the PDO so that the wa
ake sure that both the tool diameter fits in your drilled hole and the tooth height is deeper than your PDO

our tool's Tooth Height, it will break

Good

e to expand

ameter Offset is posted below.

Maximum Thread Tolerance

 0.4822
-0.03765
-0.06024
-0.01506

stments to the PDO so that the walls of the tool line up with the walls of the thread.
r than your PDO
NPT Threadmilling - Internal Hole Inputs
Machinery's Handbook Variables Name Dimension
H Height of Sharp V Thread 0.02963
TPI 27
K0 Basic Minor Dia. At Small End of Pipe 0.3339
L4 Overall Length of Thread 0.3924

Tool Info Tool Check!

Vendor Lakeshore Carbide
Model Good
Thread Mill Cutting Diameter 0.24
Thread Mill Flat Length ("crest") 0.002
Height Missing from Thread Mill 0.00173205080756888
Neck Diameter of Thread Mill 0.16 *IMPORTANT: If using a multi-too

CAD Model Dimensions INTERNAL

Top Hole Diameter 0.3583
Bottom Hole Diameter 0.3339
Taper Angle (degrees) 1.78333333333333

Data retrieved from Machinery's Handbook 30th Edition pages 2009-10 or Machinery's Handbook 28th Edition pag
 CAM Data
Pitch Diameter Offset 0.0557959
Pitch 0.037037

Tool Check!

Good

IMPORTANT: If using a multi-tooth thread mill, set this to 0

Tips on adjusting fit:

Adjusting via CAD model:
K0 will drive your PDO. Increasing K0 results in a looser fit

Adjusting via CAM:

Increase PDO…

ery's Handbook 28th Edition pages 1862-63

NPT Threadmilling - Internal Hole Inputs
Machinery's Handbook Variables Name Dimension
H Height of Sharp V Thread 0.02963
TPI 27
E0 Pitch Dia. At Beginning of Ext. Thread 0.36351
L4 Overall Length of Thread 0.3924
D Outside Dia. Of Pipe 0.405

Tool Info Tool Check!

Vendor Lakeshore Carbide
Model Good
Thread Mill Cutting Diameter 0.24
Thread Mill Flat Length ("crest") 0.002
Height Missing from Thread Mill 0.00173205080756888
Neck Diameter of Thread Mill 0.16 *IMPORTANT: If using a multi-too

CAD Model Dimensions INTERNAL

Top Post Diameter 0.3806
Bottom Post Diameter 0.4050
Taper Angle (degrees) 1.78333333333333

Data retrieved from Machinery's Handbook 30th Edition pages 2009-10 or Machinery's Handbook 28th Edition pag
 CAM Data
Pitch Diameter Offset 0.0520921
Pitch 0.037037

Tool Check!

Good

IMPORTANT: If using a multi-tooth thread mill, set this to 0

Tips on adjusting fit:

Adjusting via CAM:
Increase PDO…

ery's Handbook 28th Edition pages 1862-63

Estimated Height Missing from Threadmills
Tool Name Cutting Diameter Flat Length
Tormach 34693 0.16 0.0005
A.B. Tools TM1/4 0.188 0.003
Lakeshore Carbide 1/2-13TRMLB 0.35 0.003
Lakeshore Carbide 1/2L-SPTRMLB 0.388 0.0035
Threadmills USA TM87514 0.49 0.005
Lakeshore Carbide 3/4L-SPTRMLB 0.495 0.0045

Length of Flat Tip in Measured Tools

0.006

0.005

0.004
Length of Flat

0.003

0.002

0.001

0
0.15 0.2 0.25 0.3 0.35 0.4 0.45
Cutting Diameter

If you do not have any means to measure the tip of the tool,
this graph MAY help with a ROUGH estimate

While the value we need for thread milling is the Height that is missing from
the peak of the tool, the Length of that flat area is significantly easier to
measure.
RULE OF THUMB: For threadmills up to 0.5" cutting diameter, we found that
the Flat Length was almost always a little less than one hundredth of the
cutting diameter, so you can use that as a rough estimate.

Cutting Diameter 0.25 Notice how the cutting diameter is

Approximate ESTIMATED Flat Length 0.0025 Tool used for graphic: http://www.lak
ow the cutting diameter is not measured to the peak of the perfect triangle, but to the flat tip
for graphic: http://www.lakeshorecarbide.com/12singleprofilethreadmill34loc388cutdia12-32range.aspx
Internal Thread Profile

External Thread Profile

This sheet is for thread milling a custom sized hole, with a known thread pitch and minor diameter.
Example: 4.125" diameter hole threaded a 28 TPI
(The math is the same, but user determined inputs are required instead of data from the Machinery's Handbo

Threadmill Tool Information

Vendor Lakeshore Carbide
Model 1/2L-SPTRMLB
Thread Mill Cutting Diameter 0.388
Estimated Flat Length of Threadmill 0.0035
Neck Diameter of Thread Mill 0.25

User Inputs
Thread Pitch (TPI) 13
Minor Diameter 0.4255

Pitch Diameter Offset INTERNAL Thread

1) Pitch Diameter Offset 0.0833
2) Adjust PDO Out 0.0167
3) Adjust PDO In -0.0061
FINAL Pitch Diameter Offset 0.0939

Thread Profile Calculations

Theoretical Triangle Height 0.0666
Adjustment Amount 0.0167
Cut Depth 0.0083
Actual Triangle Height 0.0416

Thread Hole Calculations

Minor Diameter 0.4255
Major Diameter 0.5088

Threadmill Tool Calculations

Height Missing from Peak of Threadmill 0.0030
Thread Mill Tooth Height 0.138
*Machinery's Handbook 30th Edition Page 1860

Tool Check
If your final PDO is greater than your tool's Tooth Height, it will break the
tool trying to push it into the thread wall.
The below function checks this for you, if it says your tool is too small do
not try to use this tool for this thread. Try a larger tool.
Good
*Note: When choosing a tool, make sure that both the tool diameter fits
ole, with a known thread pitch and minor diameter.

ts are required instead of data from the Machinery's Handbook)

*IMPORTANT: If you are using a multi-tooth thread mill, set this to 0. Thi

(Diameter of the drilled hole you plan on milling)

Pitch Diameter Offset EXTERNAL Thread

1) Pitch Diameter Offset 0.0833
2) Adjust PDO Out 0.0333
3) Adjust PDO In -0.0061
FINAL Pitch Diameter Offset 0.1105

nal PDO is greater than your tool's Tooth Height, it will break the
tool trying to push it into the thread wall.
w function checks this for you, if it says your tool is too small do
not try to use this tool for this thread. Try a larger tool.
Good
When choosing a tool, make sure that both the tool diameter fits in your drilled hole and the tooth height is deeper than your PDO
read mill, set this to 0. This value is unnecessary as long as you are cutting a TPI that is specific to your tool.

er than your PDO