International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 5, Issue 12, December 2015)
CNC Controllers and its Related Parameter: A Review
Rajendra Rajput1, Dr. Ajay kumar Sarathe2
1
PG Scholar, NITTTR Bhopal, India
2
Associate Professor, Mechanical Engg. Department, NITTTR Bhopal-462002, INDIA
Abstract—The quality of finished work piece depends on
the relative positions between the work pieces, cutting tool,
machining process parameters. It can be achieved if a CNC
machine tool possesses sufficient strength to withstand the
cutting forces, stiffness against deformation and capability of
CNC controller. CNC controller is the heart of the CNC
machine which controls most of the functions of CNC
machine. Perfect machining in minimum time is the
requirement of manufacturing industries and along with
other hardware and machining process parameters CNC
controllers are also playing vital and an important role.
Hence, in this work an attempt is being made to investigate
and analysis of the various types of CNC controllers i.e. used
in the CNC machines especially in milling and turning. This
paper gives the detail about the three major CNC controllers
used by industry. In view of above, this paper also presents a
review of work in the area of the CNC controllers.
Keywords- CNC controller, cutting speed, machining time,
depth of cut, FANUC, SIEMENS, HEIDENHAIN
I. INTRODUCTION
CNC controllers are computer numerically controlled
(CNC) devices that control and handle machines and
manufacturing processes. They provide good capabilities
ranging from point-to-point linear control to highly
complex machining related algorithms with multiple axes
of control.CNC controllers are the main functional and
handling unit of CNC system, i.e. responsible for the
controlling all the function related to machining, for
Examples are vertical CNC milling machine, horizontal
CNC milling machine, lathe machine, grinding, EDM’s,
turning centers, flame cutting etc. It is Electronic and
computerized interface between human or software
operator and the CNC machine. CNC controllers are used
to imbed many in machine shop equipment. Some
controllers include machine retrofit kits for converting a
manual & conventional machine to a CNC machine. These
kits include common components such as, cabling, one or
more signal generators and software, controllers, and
motors. Servo motors can be precisely controlled and use
motor position feedback via resolvers or encoders.
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II. SPECIFICATIONS AND OPERATIONAL FEATURES
Specifications for CNC controllers incorporate number
of axes, level of flexibility, configuration, and features.
Some CNC controllers are specify and configured and as
computer boards. Others are housed in stand-alone
cabinets. Desktop controllers permit machine operators to
control equipment and processes from isolated, nearby
offices. Rack-mounted CNC controllers have tabs for
mounting controller components on vertical rails inside a
standard rack. Pendant controllers swing from an arm
joined to the CNC machine. Platform controllers sit on top
of an arm connected to the machine. Pedestal controllers sit
on top of an arm attached to the machine. Controllers along
with the integral screen and displays, touch screens, touch
pads or key pad are also available.
Features for CNC controllers comprise alarms and
product event monitoring, tape type storage, floppy or
diskette type storage, multi-program storage, zip disk type
storage and simultaneous control. CNC controllers may
also include tape readers, BTR (behind tape readers), and
self-diagnostic features. Language i.e. used for controller is
bitmap, conversational, DXF (drawing exchange format),
M code or G code, ladder logic and Hewlett-Packard
Graphics Language (HPGL, HP-GL).
CNC controller operation comprise cutter compensation,
polar coordinate command, linear or circular interpolation,
stored pitch error, right tapping, helical interpolation,
canned cycles and auto-scaling. Polar coordinate command
references all of the coordinates to a specific pole. Linear
and circular interpolation uses the programmed path of the
machine. Stored pitch error compensation improves
machine precision by correcting for lead screw pitch error
and other specific mechanical positioning errors. Helical
interpolation is utilized to make large-diameter holes and
internal deep cuts in work pieces. Canned cycles are
machine routines such as drilling, tapping, reaming, and
boring that involve a series of machine operations, but are
specified by a single G-code with parameters. Rigid
tapping is a CNC tapping technique which feeds a tap into
a work piece at the precise rate required for a perfectly
tapped hole. Auto-scaling translates the parameters of the
CNC program to fit the work piece.
 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 5, Issue 12, December 2015)
A.Various CNC controllers
Comparison of the main companies that
manufacturing CNC controllers is shown in TABLE I
TABLE I
Manufacturing Industries using various CNC Controllers
Manufacturer of CNC Market share Percentage
Controller
FANUC 29.5%
SIEMENS 28.5%
HEIDENHAIN 13%
MITSUBISHI 3%
FAGOR 2%
OKUMA 1%
NUM 1%
YASUKAWA 0.5%
OTHER 21.5%
So, it is clear that the most of the CNC machines are
using FANUC, SIEMENS, and HEDENHAIN controllers
having significant market share.
There are many different type of controller, which are
use in CNC machine. Like SIEMENS8T/8M/8MC,
SIEMENS3T/3M,SIEMENS810GA1,DECKELFPNC,FAN
UC6T/10M/11M,FANUC OT/18TA/TB/P,PHILIPSNC400
HEIDENHAINTNC135,HEIDENHAINTNC41,KIRLOSK
AR CRUSADER . Some more latest controllers used in
industry now a day’s FANUC 0I/16I/31/21,FANUC
160I/18I/21, FANUC21T&M , SINUMERIK 802 DSL
,SINUMERIK 802DI,SINUMERIK 810D, and then
SINUMERIk840D/840DI,SINUMERIK802DI,HEIDENH-
AIN TNC 426,FAGOR etc. Three CNC controllers on
which our study is focussed: - (1) FANUC 21T&M (2)
SINUMERIC 840D/840DI (3) HEIDENHAIN TNC 426
B. Development and features of FANUC 21T&M controller
Historical development of FANUC controller has been
started from 1960 when it developed the first controller of
220 series. its consists the two controller 2000C made for
the 2 axis CNC lathe and 3000C made for 3 axis CNC
milling machine. In 1976 FANUC 5series has been
developed and in 1979 6 series and 7 series has been come
with the bubble technology having advantage of large
memory. But this series have slow access speed. In early
1980 the 15 series has arrived to replace 12 series. It
replaces bubble memory with more reliable RAM.
In mid 1980 FANUC 10/11/12 and late of the same year
are FANUC 16/18/20/21 series come.16 series have facility 5
axis simultaneous control and 18 series having 4 axis
control ,but it is less powerful as compared to 16 series.
FANUC 30 series has arrived in early of 2000. 21T&m
having 5 axes control and have 4 controls spindle and its
can control 4 simultaneous axes.
C. Development and features of SINUMERIK 840D/840DI
In 1950s launches the first NC on to the market with
SINUMERIK. In 1960 the first genuine path PLC is
developed based on discrete electronic of the components.
In 1973, first the SINUMERIK 500C, which for the first
time i.e. based on a process computer, takes a big step
toward CNC. The Sinumerik System 7 introduced in 1976
with first CNC equipped with a microprocessor, and
enables DNC (distributed numerical control) networking.
The improved and modified version of SINUMERIK
“System 7 Sprint,” enables contours to be programmed.
Siemens launches the SINUMERIK 840D in 1994 the
system had PLC with digital drive coupling and an open
NC core. This enables the integration and management of
software components into the CNC.the SINUMERIK 810D
is provided for midlevel requirements, while the lower
application area covered by the SINUMERIK 802D. In
1984, the System 800 came along with the principle of
“openness”. The first CNC controller in this family to come
into the market are the SINUMERIK 810T/M and than
820T/M both having facility of an open human and
machine interface (HMI) for adapted user interfaces. This
family of PLCs is completed for the lower performance
range with the compact SINUMERIK 805. The modern
SINUMERIK generation of PLCs in 2004 the
SINUMERIK 840D sl. it is characterized and specify by
extreme openness and flexibility. In 2010, SINUMERIK
840D sl and the SINUMERIK 828D integrates the new
Advanced Surface motion guidance. It ensures that finer
surface finishes are achieved in shorter machining time.
This controller has simultaneous axis control capacity with
telydaignosis facility and having online ladder display.
Both manually and through machine the input can be given
to it. SINUMERIK 840D/840D having also facility of
conditional and unconditional jump, ATC, pitch error
compensation and zero offset compensation.
D. Development and features of HEIDENHAIN TNC 426
First CNC controller of the heidenhain has come in the
1968 i.e.VRZ59 bidirectional counter for only one axis.
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 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 5, Issue 12, December 2015)
In 1976, the TNC 110 and TNC 120 come along with the
numerical positioning controls for three axes. In 1996,
TNC 426 comes along with the contouring control with 5
axes. In 2004, iTNC 530 comes with the alternative
operating mode smarTNC.TNC 620 and TNC 640 was the
upgraded form of the TNC series having a facility of serial
controller interface, combined milling and turning
operation. It has the facility to change the angular position
of the spindle under the program control, Shop-floor
programmable contouring controls for milling, drilling and
boring machines, and machine centers with up to five axes.
It is able to handle more complex component as compare to
other controller. Input and machining accuracy are in a
range of 1 µm with linear movement possibility up to the 4
axes simultaneously. It’s having the facility to Returning to
the contour after an interruption.
III. EXISTING RESEARCH EFFORTS
The previous researches carried out in this area
especially focus on CNC controller, performance of
controller and process parameter of cnc machines.
Ahmet Murat PINAR, Abdulkadir GULLU [1] has
suggested algorithm for minimizing the machining time of
CNC part programs used in a vertical machining center
with the help of time calculator and cnc code editor .An
algorithm was prepared and transferred from machine to
CNC code editor with the cable (RS-232) i.e. used for
minimizing the machining time of CNC part programs used
in a vertical machining center. The time calculator
examines all the codes in the code editor, calculates the
time of all the moves in minutes and help to generate G
code by minimizing the rapid movements of the tool in
terms of the shortest tool path . As a result, it orders all the
operations formed with the same cutting tool on the x and y
axes, With the cutting parameters module, machine table
feed and spindle speed are modified using the machine
power and tool life as limiting factors for each machining
operation. As resulted reanalyzing the new CNC program
with the time calculation processor, the time save has been
seen.
Mr. Sc. Afrim Gjelaj, Dr. Sc. Avdybunjaku [2] discussed
programming and simulation of work piece through CNC
Mikron Milling machine, with using of the machine
software as such HEIDENHAIN iTNC 530,
MASTERCAM. It’s improved the productivity and
machining time of the work piece.
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The result found that Realization of processing of work
piece of any material with the CAD / CAM systems is more
than necessary considering the complicated geometry of the
work pieces, which would be difficult to calculate through
manually, but With the HEIDENHAIN iTNC 530, can be
read information through the postprocessor of
MASTERCAM or any other applied software, which
contain machines with CNC. Through MASTERCAM
software, designed and drawn after working pieces is set all
the movement trajectories of cutting Tools, such as: point
to point interpolation, linear interpolations, and circular and
spline interpolation. It’s clarified the spline interpolation
with third degree polynomial, through software to
HEIDENHAIN iTNC 530 Machine
D.Dimitrov, M.Saxer [3] had given comparison between
3-axis machining and 5-axis cutting machining with
CAD/CAM system in various case study like Hermle C40U
dynamic HSC milling centre was used with the CAM
programming with the help of utilizing Delcam’s Power
mill, found that Using 5-axis machining the routing fixture
could be machined in a single setup, with the help of this
minimize processing and lead time. This study shows
comparison of the 3axis and 5 axes machining with
different parameters.
Kotaro Nagaokaa and Atsushi Matsubarab [4] discussed
a suitable compensator design for mechanical errors
through case studies. The numerical simulation analysis
indicate that an appropriate design of a dynamic model
increase the motion accuracy of the tool center point.
Martin Eckstein, Ildiko Mankovab [5] describes a new
approach in real-time monitoring for drilling bolt holes in
Inconel718. By extracting and processing controller data
with non-linear algorithms. Process data origination from
the NC of a SINUMERIC 840D controller
Sergej N.Grigorieva, A.A. Kutinb, V.V.Pirogovc [6]
analyzed a method to simultaneously increase the accuracy
and decrease the calculation time for complex tool path
programming in multi-axis machining centers. The
algorithms developed for the CAD/CAM software that
allows for NC programming and machining on 5-axis
centers employing any design model. That is improving the
processing time in the complex job.
Abhishek Kumar Saroj, Dr. S.C Jayswal [7] described
effect of different parameters on tool path. They analyzed
different parameters with respect to machining time. For
this analysis MASTERCAM software is used for collecting
the data and analysis is based on the CNC end milling
process.
 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 5, Issue 12, December 2015)
Researcher took sculptured surface for roughing
operation. Details of generating of this surface shows that
different parameters are required like optimal diameter of
tool, step over percentage, feed rate, depth of cut, step
down relationship etc. So for finding the optimal values,
these parameters are used with software.
S. Daneshmand, M. Mirabdolhosayni and C. Aghanajafi
[8] investigated the potential ways to reduce machining
time with the help of CATIA & CAM, resulted of
machining time is reached minimum when zigzag strategy
is used tools paths through End Mill.
Khairul Akmal Shamsuddin,A. R. Ab-Kadir,Mohd
Hairizal Osman[9] presented a comparison of milling
cutting path strategies for thin-walled aluminum alloys
5083 with the help of MASTERCAM XMR2 with end
milling procedure by using visual charts. The best
machining strategies to achieve good quality surface
roughness of upper and lower areas is parallel spiral
strategy out of different combinations. The final results
show that the constraints on the surface roughness, time of
machining and thickness related accuracy are very
significant to obtain a high productivity fabrication of thin
walled aluminum alloys. According to the experimental
results, the most accurate thin walled fabrication in mean of
thickness accuracy within the range and limit of specified
cutting condition is true spiral cutter path strategy.
Rakesh Prajapati, Avadhoot Rajurkar, Vijaykumar
Chaudhary [10] suggested optimization of tool path for
turbine blades in vertical machining centre (VMC) with
Master CAM software results in reduction of machining
time. Different contouring tool paths are simulated in
Master CAM prior to machining of turbine blades.
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Cutting Parameters used for machining are spindle speed
(SS), feed, tool diameter, plunge-rate (PR), and depth of cut
(DOC). The comparison of experimental machining and
simulation results describe that the best tool path
significantly depend on the geometry of the work piece
(deigned) and the cutting conditions.
Gustavo M. Minquiza, [11] had proposed the
comparative study realized to contrast between the part
programming code generated by the two different-different
CAM systems and one other. This comparison addresses in
the particular tool path, but also includes number of lines,
cycle time and energy consumption. The results show
comparison between the tool paths generated by each
approach and shows reducing cycle time and energy
consumption. 3 different type of NC program have been
generated for the experiment. Simulations carried out with
the CATIA and MASTERCAM software used produced
different NC part programs for the study. Different process
parameters and machining strategies produced an accuracy
of the 96% and 97% respectively, against the real machined
cycle time. On the basis of experimental analysis as
concluded by the energy consumption is influenced by the
cutting tool, response time between the controller and the
servomotors of the machine tool, number of flutes and the
feed rate.
The specific analysis performed in the different areas as
discussed by this review paper in the Table II.
 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 5, Issue 12, December 2015)
S.No. Name of Year Contribution Controller/ parameter
Researchers software used
1 Ahmet Murat Pinar et. al. 2005 Suggested an logic algorithm for Feed
minimizing of the machining time on --- Tool geometry
VMC Cutting speed

2 Sc. Afrim Gjelaj et.al. 2010 Use of HEIDENHAIN iTNC 530, HEIDENHAIN Cutting speed
MASTERCAM for improving the iTNC 530 Tool geometry
productivity and machining time of
the workpiece
3 Dimitrov D. et.al. 2012 Find the comparison in between 3axis Delcam Machining time
and 5 axis CNC milling machine Lead time
based on various type of case study
4 Kotaro Nagaokaa et.al. 2012 discussed a suitable compensator Feed forward Feed
design for mechanical errors through (MR-FF) controller Cutting speed
case studies
5 Martin Ecksteina et.al. 2012 Investigations into a new non-linear SINUMERIC 840D Surface quality
algorithms approach in real-time MASTERCAM Machining time
monitoring for drilling bolt holes in Cutting speed
Inconel718
6 Sergej N. Grigorieva et.al. 2012 Developed algorithms for the Surface quality
CAD/CAM software that decrease the ---
calculation time of software for
complex tool path programming in
multi-axis machining centers
7 Abhishek K Saroj et.al. 2013 Investigation of machining SINUMERIC 802s Feed rate
parameter with the tool path with the Machining time
help of CNC controller Surface roughness
8 S. Daneshmand et.al. 2013 Investigated the minimization of CATIA Machining time
machining time with zig zag tool path MASTERCAM Feed, Depth of cut
strategy Cutting speed

9 Khairul akmal Shamsuddin 2013 Compared the milling cutting path MASTERCAM Surface quality
et.al. strategies for AL alloys 5083 with the X MR2 Feed
help of CAM software

10 Rakesh Prajapati et.al. 2013 Investigated to Optimization of the CATIA Spindle speed
tool path and machining parameter MASTERCAM Feed, depth of cut
with software and FANUC controller FANUC 0i-TB Diameter of tool Plunge-
rate

11 Gustavo M .Minquiza et.al. 2013 Investigate into comparison of energy MASTERCAM Efficiency
consumption of the 2 CAM system FANUC Machining time

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 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 5, Issue 12, December 2015)
IV. CONCLUSION
The Investigation in this area revevles that the
performance of the controller can depends on so many
parameters like feed, cutting speed, depth of cut, surface
roughness, lead time, tool geometry etc. In view of above
literature it can be concluded the main objective of these
effort is to minimize the cost related to the machining.
Hence in this work an attempt is being made to compare
the different controllers. The review paper concludes the
broad areas and subareas where controller perform vital
role. This paper also identifies the research area of CNC
controllers. And it works on identifying CNC controllers,
various parameters for the CNC controller and also suitable
software that can be used with it.
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