THREAD PLUGS

For the Go plug pitch

diameter, add the MAX.
amount of plate. For the Not
Go pitch diameter, add the
MIN. amount of plate. For the
majors of work plugs,
increase the major diameter
on Go work plug by using half
the MAX. amount of plate. On
Not Go work plugs, increase
the major diameter by using
half the MIN. amount of plate.
Example
Based on .0002 to .0003
allowance per side (multiply
by 4)
.0002 X 4 = .0008 MIN.
.0003 X 4 = .0012 MAX.
1/4-28 UNF 2B B/P
Basic GO P.D. .2268 + .0012
MAX. = .2280 Go P.D.
Basic NOT GO P.D. .2311
+.0008 MIN. = .2319 Not Go
P.D.
Basic GO major .2500 +
(.0012 / 2) = .2506 B/P Go
major.
RATIO OF PITCH DIAMETER CHANGE TO THICKNESS OF COATING (60 ONLY)
Basic NOT GO major .2466 +
(.0008 / 2) = .2470 B/P Not
t = thickness of coating
Go major.
a = pitch diameter change due to coating
0.25a = t and a = 4t or the pitch diam. of a 60 thread changes by four times the thickness of the
coating
BEFORE PLATING RATIOS FOR PITCH DIAMETER
60 thread = 4:1
29 Acme = 8:1
7-45 Buttress = 4.3138:1
14 30'-5 Buttress = 11.9311:1
10 Square thread = 23:1
THREAD RINGS
For the Go ring, subtract the MAX. amount of plate. For the Not Go ring, subtract the MIN. amount of plate. For the minors of thread
rings, decrease the minor diameter on the Go thread ring by using half the MAX. amount of plate. On Not Go thread rings, decrease
the minor diameter by using half the MIN. amount of plate.
Example
Based on .0002 to .0003 allowance per side (multiply by 4)
.0002 X 4 = .0008 MIN. .0003 X 4 = .0012 MAX.
1/4-28 UNF 2A B/P
Basic GO P.D. .2258 - .0012 MAX. = .2246 Go P.D.
Basic NOT GO P.D. .2225 - .0008 MIN. = .2217 Not Go P.D.
Basic GO minor .2103 - (.0012 / 2) = .2097 B/P Go minor.
Basic NOT GO minor .2148 - (.0008 / 2) = .2144 B/P Not Go minor.

Anodic CoatingsWhen calculating dimensions for pre-anodize gaging, a modification from the two above examples
given, must be made.
For example, when calculating the increase in dimensions for the pre-anodize work plug gages, the value of thickness
amount of the anodize applied, must be, for gage calculations purposes, reduced by one half, i.e., if the minimum and
maximum applied anodize thickness dimensions were, .0004 to .0006 per surface, the values used in the calculations,
would be only one half of the application, or .0002 to .0003 per surface. The results, in this example, would then be the
same values, as the example shown above for the thread plugs. For thread rings, the same procedure would be utilized, in
reverse. Reference Data: MIL-A-8625F, page 16

Accurate Formula To Compute The Pitch And Major/Minor Diameters For

Before Plate Thread Plugs And Thread Rings*

The Effects of Plating.. What you really need

to know!
The KATO Tech Group receives many technical inquiries on the usage of various platings and
coatings applied to helical coil inserts. In general, platings and coatings are used to protect
components from corrosion and other environmental factors. They can also provide increased
wear resistance, dimensional stability, increased hardness, and lubricity. The lubricity
characteristics can minimize friction and galling with the mating screw or bolt, as well as
improve installation properties of the inserts.

Figure 1: Plating build-up on various surfaces.

The specifications covering free running and locking Tangless Inserts, NAS1130, as well as
locking Tanged inserts, NASM21209 both give the user the option of specifying either Cadmium
Plating in accordance with QQ-P-416, or Dry Film Lubricant (Molybdenum Disulfide) in
accordance with MIL-L-46010.
Stainless steel helical coil inserts without platings or coatings can be used in environments with
temperatures up to 800 F. However, cadmium plating and dry film lubricant have limited high
temperature capabilities. Please contact the KATO Tech Group for plated or coated inserts used

in temperatures above 450 F. The Cadmium Plating and Dry Film Lubricant Coatings should
not be used in vacuum type applications due to their out-gassing properties.
When designing threaded assemblies, compensation must be made in the tolerances for plating
buildup, depending on the plating thickness. For discussion purposes, we will show the effect of
plating buildup on various surfaces in the following examples, assuming a plating thickness of
0.0003 inches is used.
Figure 1 shows the buildup of plating and how it increases the overall dimensions of each
example shown. In the case of a simple surface, the plating increases the thickness by .0003 in.
Plating on a diameter increases that diameter by 2 x .0003 = .0006 in. Plating on an internal or
external thread is a bit more complicated. Because of the 60 thread form, the buildup of plating
on the pitch diameter is 4 x .0003 = .0012 in. The thread geometry is shown in Figure 2.

Figure 2: Plating build-up on a 60 thread form.

Heres the part that may be new to you. Figure 2 details the plating build-up on a thread form.
Again because of the 60 thread geometry combined with the fact that there are four sides being
plated, the buildup of plating on the pitch diameter of a helical coil insert is 8 x .0003 = .0024.
In many cases it is necessary to compensate for plating on the tapped hole or insert by using STI
taps with a larger pitch diameter. The tap manufacturer does this by specifying a larger H limit
on the tap, depending on the amount of compensation needed for plating thickness. Each H limit
represents 0.0005 inches over basic pitch diameter.
For more information on H limits and Class of fit, see Article 0702, The Science behind Pitch
Diameter and Class of Fit.
Plating an insert is also a solution for correcting an oversize tapping condition. If an STI tapped
hole was tapped oversize by .001 in., the final assembly could be brought back into specification
by plating the insert with .000125 in. plating thickness, i.e. (8 x .000125 = .001).

If you have any questions contact the KATO Tech-Group. To view more technical articles please
visit KATOpedia.

The Science Behind Pitch Diameter and Class

of Fit
The KATO Tech-Group is frequently called upon to explain the differences in the various classes
of fit for both inch and metric threads, and how they relate to threaded insert assemblies. So, we
decided to dedicate this article to this subject by creating a simple explanation that we think will
be a useful tool for our distributors, as well as end users of our inserts. We will focus on Pitch
Diameter and how the tolerance range dictates the Class of Fit.

Pitch Diameter:

Figure 1A: Diameter of Imaginary Cylinder

Lets take a quick step back, and define the pitch of a thread. Pitch is the distance from a point on
a screw thread to a corresponding point on the next thread measured parallel to the axis of the
thread, see Figure 1b
Pitch (in inches) = 1/ (Number of threads per inch) Example: 4-40 UNC: P= 1/40 = 0.025 inches
The pitch on metric threads is also the distance from thread to thread corresponding points,
except that the distance from thread to thread is measured in millimeters (mm). And, metric
thread sizes are also expressed differently than inch threads.
Example: Thread size M10x1.5
Pitch (in mm) = 1.5
Class of Fit:

Figure 1B: Pitch Diameter Definition

The class of fit defines the tolerance range of thread dimensions including major, minor, and
pitch diameters of internally or externally threaded parts. We will focus on the pitch diameter
tolerances to keep it simple. Typically there will be a number and letter following the thread size
to designate the class of fit. On inch sizes, the number 2 or 3 expresses the class of fit, and the
letters A or B designate external or internal threads respectively. The Class 2A and 2B
threads are typically referred to as commercial quality. This class of fit has a broader tolerance
range and it is intended for general fastener usage.
The Class 3A and 3B threads are referred to as precision quality, and sometimes aerospace
quality. This class of fit has a tighter tolerance, and is intended for applications where precision
and thread accuracy are required. As precision equipment and gauging are necessary to produce
these closer tolerances, higher manufacturing costs are a consequence of specifying this class of
fit.

In many cases it is necessary to compensate for plating on the tapped hole or insert by using STI
taps with a larger pitch diameter. The tap manufacturer does this by specifying a larger H limit
on the tap, depending on the amount of compensation needed for plating thickness. Each H limit
represents 0.0005 inches over basic pitch diameter.
The best way to visualize the differences in screw thread classes of fit is shown on the bar graph
in Figure 2. This example shows the pitch diameter limits for -28 UNF internal and external
standard threads.
Metric threads use a different system for pitch diameter tolerances. And, this system is a bit more
complicated than that used for inch threads. The tolerance class consists of a tolerance grade and
tolerance position. The tolerance grade is specified by a number that controls the pitch diameter
(and crest diameter) tolerances. The crest diameter is the major diameter on an external thread,
and the minor diameter on an internal thread. The tolerance positions are designated by letters,
upper case letters for internal threads, and lower case letters for external threads.
Example:
Tolerance Class
Thread Type Pitch Diameter Crest Diameter
External Thread 4h5h
Internal Thread 4H5H

When the pitch and crest diameter tolerances are the same, the designation is only written once.
For example; 4H4H need only be written as 4H. With metric threads, the larger tolerance grade
number indicates a broader tolerance range. For example; 4H is approximately equivalent to
Class 3B (precision quality), and 5H is approximately equivalent to Class 2B (commercial
quality). Please see Figure 3 for an example of pitch diameter limits for M6x1 internal and
external standard threads.

Pitch diameter tolerances are tighter on tapped holes intended for helical coil inserts. These holes
carry the designation STI (Screw Thread Inserts) after the thread size. The reason for this is
due to the fact that the final assembly has to meet Federal Thread Standards, so the tapping
tolerances have to be tighter to account for the insert wire tolerances. The class of fit of the
installed insert is controlled by the class of fit of the tapped hole. KFS offers STI taps for inch
threads in both Class 2B and 3B tolerances, and for metric threads in Class 4H and 5H
tolerances.
If you have any questions contact the KATO Tech-Group. To view more technical articles please
visit KATOpedia.