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How Power Drills Work


BY CLINT PUMPHREY
Browse the article How Power Drills Work

Power drills have a variety of


uses. See more pictures of
power tools.
MARTIN POOLE/GETTY IMAGES

It was a snowy December night in 2003 when Ben King fell down a flight of stairs in his Hailey,
Idaho, home. King suffered a severe head injury and needed to be airlifted to the nearest
neurosurgeon. But deteriorating weather conditions made it impossible for the helicopter to land
near King's home, so the injured man had to be driven to Shoshone, 43 miles (69 kilometers)
south of Hailey, to meet it. When paramedics finally transferred King to the helicopter, an
intracranial bleed had caused the pressure in his head to rise to a critical level. That's when Dr.
Keith Sivertson made a bold but calculated decision. He grabbed the best surgical tool available
in a snowy church parking lot in rural Idaho -- a Makita cordless power drill -- and bore a hole in
King's skull, relieving the pressure and ultimately saving his life.

Of course, roadside surgery is one of the more unconventional uses for power drills, which are
among the most common and versatile power tools on the market. The drill's mechanism is
actually quite simple: A trigger switch activates an electric motor, which in turn drives a rotating
chuck. Numerous accessories can fit into in the chuck, allowing the drill to bore holes, drive
screws, and sand, polish, and grind a wide variety of materials. Today's drills offer a wide variety
of features that make these tasks easier and more accurate, including high-capacity nickel-
metal-hydride batteries, variable speed triggers, and even built-in levels and LED work lights.

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Power drills have not always been so sophisticated. Wilhelm Emil Fein of Stuttgart, Germany,
developed the first handheld model in 1895. At 16.5 pounds (7.48 kilograms), the cumbersome
drill weighed nearly five times as much as those manufactured today, but it's widely considered
to be the world's first handheld power tool. Over the next several decades, Fein and other
manufacturers made significant improvements in the power and affordability of power drills, but
they were still tethered by their power cord. It wasn't until 1961 that Black & Decker introduced
the cordless electric drill, a self-contained unit powered by a nickel-cadmium battery. Since then,
cordless power drills have become an essential part of construction sites and personal toolboxes
everywhere.

Though you may never save lives with your power drill like Dr. Sivertson, the following sections
will show you how to choose the drill that's right for you and how to make the most of it.

Power Drill Parts


The power drill is remarkably easy to use, so it makes sense that it's a remarkably simple
machine. Basically, a squeeze of the trigger turns on the electric motor, which then rotates the
drill or screwdriver bit. However, advancements in drill design and control mean there's a little
more to it than that.

The first thing you need to know about power drills is how they're powered. Current models are
both corded and cordless; corded drills are rated in amps, while cordless drills are measured
in volts. The higher the amperage or voltage a drill has, the more power it has. More power
creates more torque, or rotational force, on the drill or screwdriver bit.

A trigger switch, located in the same place you might expect the trigger of a pistol, gets the drill
moving. Today's drills usually have a variable speed trigger, meaning that the harder you
squeeze, the faster the electric motor spins the drive shaft. Cheaper models run at a single top
speed, but pricier models offer between two and four maximum speed settings, usually ranging
between 200 and 2,000 rpm. With a variable speed trigger and multiple speed settings, you can
operate your drill between zero rpm and the top speed of each setting.

From the electric motor, the drive shaft transmits the rotation through the clutch, which regulates
the drill's torque. Many drills have an adjustable clutch, some with as many as 24 settings. The
higher the clutch setting, the higher the torque a drill puts out. When the drill reaches the preset
clutch setting, the clutch disengages the drive shaft, allowing the motor to turn but not the drill or
screwdriver bit. This results in a clicking sound.

The last major part of a drill is the chuck, a mechanism into which you fasten the drill or
screwdriver bit. Until the 1980s, chucks were keyed, meaning you needed a special tool to
tighten them. Today, nearly all drills are keyless. The gear once tightened by a key is fitted with a
grip, allowing the user to secure the bit by hand.

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Read on to learn about selecting the right drill or screwdriver bit for the job, and discover ways in
which you might not have thought to use power drills.

IMPACT DRILLS
Impact drills, also known as hammer drills, produce a hammer action in
addition to the normal rotation of the chuck. Two parts unique to the impact
drill create this force: the impact mass, which is rotated by the electric motor,
and the anvil, which holds the bit. At first, the impact mass and anvil rotate
together. But when the anvil meets sufficient resistance, the impact mass
slips behind the anvil's wings, compressing a spring behind the impact mass.
When the impact mass clears the anvil's wings, the spring decompresses,
creating the hammering action. This process is repeated at a rate of up to
56,000 beats per minute [source: DeWalt]. The rapid downward force gives
the drill more torque, making it more powerful than its hammerless cousin.

Power Drill Accessories


Of course, a power drill is useless without accessories. These pieces, which are designed to
fasten into the chuck, can accomplish a surprising number of tasks. The most common kinds of
accessories are drill and screwdriver bits.

Drill bits, like the drills that turn them, come in a variety of shapes and designs. The most
versatile of these is the twist bit, a cylindrical shaft with a cutting edge wrapped around it like
stripes on a candy cane. These bits typically range in size from 1/64 inch to 1/2 inch and are
commonly used to bore holes in wood and metal. Spade bits are the cheapest and most effective
way to drill larger holes in wood. The sharp, flat end of these bits is able to scrape away the
surface of the wood as it cuts, creating holes between 1/8 inch and 2 inch in size. Brad point and
Forstner bits are specially designed to drill cleaner and more precise holes, but they're generally
more expensive than twist and spade bits. Drilling holes in concrete or masonry requires special
tungsten-carbide-tipped bits; impact drills are especially well-suited for this task.

There are also many different types of screwdriver bits. Phillips head bits are the most common,
as these kinds of screws are used extensively in construction and home improvement
applications. Other kinds of screwdriver bits include flat head, torque, spanner, tri-wing, hex and
torx. Each is a variation on a simple concept: the bit is shaped to fit into a corresponding slot on
the head of screw so it can be effectively tightened and loosened.

With the right accessory, drills can emulate almost any tool in the shed. Drum and disc sanding
bits can sometimes be used to do the work of much larger and more expensive machines. Other
bits can polish, cut or grind materials; larger attachments can even stir paint, mix concrete and
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serve as a handheld earth auger. Kits are available that harness the power of a drill to create
makeshift machines like a lathe or a water pump. While these uses show the incredible versatility
of power drills, their specialty is still boring holes and driving screws; they aren't perfect
substitutes for the tools they're meant to imitate.

Now that we know all the parts and accessories associated with power drills, let's learn how best
to use them.

DRILLS BIG AND SMALL


Drills come in all shapes and sizes. Those used in micromanufacturing, like
Cameron Micro Drill Presses' Model 2007-TC CNC micromachining center,
can drill a hole 0.02 inch (0.5 mm) in diameter and 1/2 inch (1.3 cm) deep
[source: Richter]. On the other end of the spectrum, oil rigs have the
capability to drill extraordinarily deep holes. The Tiber well, operated by
British Petroleum, was drilled to a depth of 35,000 feet (10.7 km) [source:
Pepitone].

Using a Power Drill


While power drills have made easy work of boring holes or driving screws, getting it just right can
be a bit tricky. By following a few simple steps, you can get quality results on the first try.

With both drilling and screwdriving, the hard part is getting started. Drill bits, especially larger
twist bits, have a tendency to wander across the surface of the material when you first start
boring. To ensure a precise entry point, first draw cross lines to indicate where you want to drill
the hole. Then use a punch -- a small tool used to stamp or pierce objects -- to create a dimple at
the intersection of the lines; this will keep your bit in one place as you begin to spin the shaft.
Start slowly, then speed up the drill as the hole gets deeper.

Screws have a similar tendency to wander at first. Tapping them in place with a hammer or
drilling a small pilot hole before driving them in can help to ensure accuracy. When you're ready
to drill, adjust your clutch setting depending on the density of the wood; a high torque setting can
cause the screw head to sink in too far or break off completely. If you're loosening or removing
screws, a drill's reverse function can be particularly helpful.

While power drills are simple, easy-to-use tools, this doesn't mean that they can't be dangerous if
operated improperly. Most manufacturers recommend using eye protection when operating the
drill and keeping your hair, clothing, gloves and jewelry away from the drill's moving parts. To

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prevent fire and electric shock, pay attention to the electrical power source. Inspect cords for
damage regularly, and check any replacement batteries to ensure compatibility with the drill and
charger. Don't operate corded or cordless drills in the rain or snow.

As with any machine, your drill will last longer if you maintain it well. Most manufacturers
recommend using clean cloths to remove dirt, dust, oil, and grease from the drill, while keeping it
away from commercial solvents and petroleum-based products, which may damage the plastic
casing. Store fully-charged batteries at room temperature, and charge them every month or two
when you're not using them. While all batteries eventually wear out, these steps will help
lengthen their life.

With so many features and accessories, how do you find the drill that's right for you?

HELPFUL HINTS
The following tips will help you get the best results from your power drill
projects.

For a cleaner hole, place a piece of scrap wood behind the


board into which you are drilling. This will prevent the wood
fibers from tearing as the bit exits the board.
Drilling a straight hole can be a challenge. Set up two
squares perpendicular to the board into which you're drilling and
try to line up your drill bit parallel with those squares.
If you need to drill to a particular depth, place a small flag of
duct tape on the bit at the desired depth. When the tape begins
to sweep away the wood shavings around the hole, stop drilling.
Driving a screw into dense wood can be a chore. Rub the
screw's threads with bar soap to save yourself some elbow
grease.

Choosing a Power Drill

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Choosing the right power drill can make a


huge difference with your home
improvements.
JUPITERIMAGES/THINKSTOCK

With dozens of models to choose from, deciding which drill to buy can be an overwhelming task.
The key is to choose a drill that fits your needs.

One of the first things you need to consider is the drill's power supply. Corded drills never have to
be recharged and are often more powerful than their cordless counterparts. But then there's the
cord -- it gets in the way and restricts use to jobs near an electrical outlet. Cordless models can
be taken almost anywhere but can't run forever. For this reason, it's a good idea to purchase an
extra battery so one can charge while the other is in use. Battery voltage ranges from 9.6 to 18;
higher voltage commands more torque, but 12- to 15.6-volt models are typically powerful enough
for everyday use. High voltage, along with high amp-hour (Ah) ratings, guarantee longer battery
life.

But how does the drill actually perform? We've already mentioned a number of features that'll
make your home improvement experience more productive and enjoyable. First is the variable
speed trigger which allows greater control over the speed of the bit. An adjustable clutch is also
important, particularly for driving screws. A drill operating with too much torque has broken many
a screw head. It's also important to choose a drill that's right for the tasks for which you plan to
use it. One way to determine this is by chuck size, or the size of bit that the chuck can accept.
Common sizes are 1/4, 3/8, and 1/2 inch (metric chucks are 6, 8, 10, or 13 mm); the higher the
diameter, the higher the torque. For most household tasks, the 3/8 inch (10 mm) chuck diameter
provides plenty of torque, but if you plan to drill into more dense materials like metal or concrete,
you might consider something a little larger. Finally, you'll have to decide if you want a drill with
the impact feature. While this doesn't provide any advantage for drilling holes in wood, it makes
screwdriving easier and is necessary for drilling in concrete or masonry.

Another criterion that often gets overlooked is the feel of the drill. When choosing one, pick it up
and see how it handles. Is it too heavy? Does it feel balanced in your hand? Is the speed setting
easy to adjust with your thumb and index finger?

With these considerations in mind, you'll be ready to get drilling. For lots more information on
home improvement, see the links on the next page.

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More Great Links


Lowe's: Choosing a Power Drill
This Old House: Choosing a Cordless Drill

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Black & Decker. "About Black & Decker." (Dec. 22,
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Bosch Power Tools UK. "Cordless Drill/Driver." (Jan. 3, 2010)http://www.bosch-
do-it.co.uk/boptocs2-
uk/DIY/Tools/GB/en/hw/Cordless%20Drill/Driver/95236/index.htm
"Cordless Drills and Drivers." Consumer Reports Buying Guide. p. 61-63. 2009.
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Furber, Matt. "ER Doc, Rescue Celebrated." Idaho Mountain Express and Guide.
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