What should the clearance for a counterbore pilot be?

The clearance for a counterbore pilot is crucial for achieving proper alignment and fit during machining operations. A clearance of 0.002 to 0.005 inches is the standard recommendation because it allows for enough space to accommodate variation in part dimensions and alignment without compromising the precision of the fit. This range ensures that the counterbore pilot can easily enter the counterbore while maintaining stability and accuracy during machining.

Too little clearance could lead to binding or misalignment, while too much clearance might result in a loose fit that could affect machining quality. Hence, the established range provides a balanced approach that promotes effective and efficient machining processes.