Innovations at the Intersection of Generative Design and Additive Manufacturing: Trends, Challenges, and Future Directions K. Karthik, Ramesh Kumar R, S. Balaguru EPJ Web of Conferences, 2026 The contributions of generative design and additive manufacture will be enormous to innovations in the field of modern engineering and industrial applications. A literature survey of recently published papers to understand major advances in deep learning applications, manufacturing optimization, and industry-derived implementations is presented by the current paper. Besides, it depicts significant progress in two domains of stress-driven generative design for lattice structures and real-time process simulation through digital twins to be developed along with manufacturing aware algorithms. This work points to an increasing direction of the generative design method towards sustainability and bio-inspired approaches. Besides, the study discussed coyote issues in standardization, reliability assessment, and mass production implementations. Hence, this review will be a great source of information for the researchers and the practitioners and also serve as an opening of new and promising research avenues in generative design for additive manufacturing.
Generative AI–driven topology optimization for mass reduction in aerospace drone structures Ramesh Kumar R, Shakthivel S Results in Engineering, 2026 • Generative AI-driven SIMP topology optimization achieves 70% mass reduction in aerospace drones • Density-based FEA yields 83.94% compliance reduction while maintaining safety factor of 2.0 • 16 optimized designs validated across three materials and manufacturing constraint scenarios • Machine learning regression models confirm optimization accuracy with R² values exceeding 0.95 • Aluminum alloys achieve optimal mass efficiency (0.08 kg) for weight-critical applications The paper introduces a topology optimization framework for the structural design of aerospace drone components, where density, based topology optimization is integrated with exploratory machine learning for post, optimization performance analysis. Through density-based topology optimization using SIMP methodology, 16 design results were created for the combination of three materials (Aluminum 6061, Cobalt Chrome, Aluminum AlSi10Mg) and three manufacturing methods (3-axis milling, additive manufacturing, unrestricted). The optimization resulted in a reduction of compliance by 83.94% while the volume was reduced by 70% with a safety factor of 2.0 being maintained. The von Mises stress (13.38-15.71 MPa) and displacement (0.03-0.11 mm) of all designs were very close to each other and within the acceptable aerospace limits. In order to assess the practicability of surrogate, based performance prediction, six machine learning regression models (Linear Regression, Random Forest, SVR, Gradient Boosting, XGBoost, and Decision Tree) were used in an exploratory way; however, the findings serve only as a demonstration of the concept since the dataset size was limited. Aluminum alloys achieved the top mass efficiency (0.08 kg) for weight, critical applications, while Cobalt Chrome provided high safety factors (37.30, 43.44) for heavily stressed parts. The results show a significant weight reduction for the single static load case considered. On the other hand, the paper also acknowledges that multi, load and dynamic scenarios are required for real aerospace validation.
Enhancement of exhaust manifolds using hybrid Graphene-TiO₂ nano fluids in multi-cylinder diesel engines: A CFD study on TiO₂ advantages Ramesh Kumar R, Channa Keshava Naik N, Ali B.M. ALI, Bharath L, Ahmed Kateb Jumaah AL-NUSSAIRI, Vijaykumar B P, Amir KHAN, Aseel SMERAT, Anwar KHAN Journal of Thermal Engineering, 2026 This work is about graphene-TiO hybrid nanofluid used for cooling a diesel engine exhaust manifold via coupled CFD simulations and experimental validation.The authors of this paper confirmed grid independence at more than 800 mesh elements with the pressure converging within -6 to 4 Pa.At 4.102 m/s velocity, the hybrid nanofluid caused a 7.016 Pa pressure drop, whereas the same for the conventional coolants was only 4.620 Pa thereby, the 52% rise in the pressure differential that correlates with the convective mixing enhancement.Streamline visualization depicted flow regularity improvement with the use of nanofluids, whereas turbulent kinetic energy increased steadily from 0.05 to 0.25 m/s over the 0-4 m/s velocity range, thereby promoting heat transfer directly.The enhancements in thermal conductivity of 5% and the heat transfer coefficients of 6% (with respect to the baseline fluid) have made it possible to reduce the peak manifold temperature by 340C.The pressure gradient or the change in pressure remained very stable (within 6 Pa) all over the domain, which is a clear indication that the hydrodynamic behavior was under control.
Exhaust manifold performance enhancement using nano fluids a design and CFD investigation for four stroke petrol engines R. Ramesh Kumar, K. Karthik, P. V. Elumalai, Nambiraj Masilamani, A. Saikumar, Aschalew Cherie Scientific Reports, 2025 This paper presents a trivial approach in which the temperature of the exhaust manifold decreases due to the changes in the fuel composition. The authors have defined Nano fluids as a modern class of fluids that consist of suspended solid Nanoparticles in fluids. Also, they have shown that noise reduction is possible with Nano fluids. Using Computational Fluid Dynamics (CFD) simulation technique, optimal designs are generated and analyzed to assess their ability to withstand different loads. For this particular process, the 4-cylinder engine exhaust manifold having 4 inlet ports and 1 outlet port was selected. This approach makes the design process more efficient and vibrational sources less powerful. Besides, petrol engines using Nano fluids have been reported to perform better. This study is on the performance improvement on exhaust manifolds using Nano fluids in four-stroke petrol engines. Key findings include a 13.5% drop in noise and better thermal management with aluminum oxide Nano fluids. CFD simulation validated these findings, showing a significant reduction in temperature and vibration level. It indicates the potential available from Nano fluids toward increasing engine efficiency and durability against emission. Advanced materials and innovative designs have been incorporated into this study to construct reality in taking these improvement promises closer for future automobile developments.
CFD Analysis of Hydrogen Gas Behaviour in a Multi-Zone Flow System: A Parametric Study Ramesh Kumar R., Yogeesha H. C., Channa Keshava Naik N., Abhishek Bhattacherjee, Abhijit Bhowmik, Mayur Dondiram Pawar, Sameer Algburi, Salah Jasim Mohammed, Hasan Shakir Majdi, Sher Afghan Khan Cfd Letters, 2025 The ANSYS CFD analysis made use of hydrogen in this study. The investigation aims at understanding the behaviour of hydrogen gas in such interactions with the inlet air and other fluid zones around it. Such research took advantage of sophisticated simulation tools to offer useful insights into gas flow and mixing patterns, thereby justifying why hydrogen could possibly become an alternative fuel one day (hydrogen is future-oriented). In addition, a model was created to establish the interaction between combustion involving hydrogen as well as tanks of inlet air. This was done on volumes for such tanks. Many factors affect performance and efficiency for different operational conditions of hydrogen gas that were explored through elaborate simulations. These findings should improve our comprehension about physics involved which plays an important role in enhancement of systems using hydrogen for power generation and also help various industries' operations using this element in their processes. It is research that looks at the complicated flow structures and behaviours that arise in fluid domains to uncover key parameters for better designs and more efficient hydrogen systems. Consequently, it is expected that the present study will help future designs of hydrogen technology so that they play a part of sustainable energy source.
Design and Simulation of a Boom with a Cylinder in an Excavator using MATLAB Controllers R. Sathish Kumar, J.M. Babu, K. Karthik, B. Marxim Rahula Bharathi, P.V. Elumalai International Journal of Vehicle Structures and Systems, 2024 Excavator working devices are essential for the excavation process in construction projects. The performance of an excavator heavily depends on the design of its working device. In the past, the traditional design method was used to design these devices, which was characterized by low-quality designs, heavy workloads and long design cycles. However, with the increasing development of virtual prototyping technology, this traditional design method is being replaced by the virtual prototyping method. The virtual prototyping method involves the use of CAD software to generate a virtual model of the excavator working device. This model is then used to simulate the mining processes of the excavator and kinematics simulations are carried out to determine the excavator performance of working device.
Dynamic Analysis of an Excavator using a Robotic Arm Through MATLAB and Adams Simulations R. Rameshkumar, Bachina Harish Babu, P. Ravichandra Ganesh, Syed Riyaz Ahammed, J.M. Babu, et al. International Journal of Vehicle Structures and Systems, 2024 In a mechanical excavator, the properties of the working device are complex and therefore require a systematic approach. The study of these dynamics typically begins with the mechanical properties of the excavator in the working condition. To break the integrated constraint of the system dynamics, the Lagrange equation is employed, allowing for computation of the maximum dynamic cargo and dynamic cargo measure. These values give a dependable base for determining the necessary structural strength required to safely operate the excavator. This knowledge can assist in optimizing excavator performance and efficiency, ultimately resulting in improved excavator technology and practical applications.
Enhancing automotive cooling systems: composite fins and nanoparticles analysis in radiators R. Ramesh Kumar, K. Karthik, P. V. Elumalai, R. Elumalai, Davannendran Chandran, E. Prakash, Nasim Hassin Scientific Reports, 2024 Composites are driving positive developments in the automobile sector. In this study investigated the use of composite fins in radiators using computational fluid dynamics (CFD) to analyze the fluid-flow phenomenon of nanoparticles and hydrogen gas. Our world is rapidly transforming, and new technologies are leading to positive revolutions in today’s society. In this study successfully analyzed the entire thermal simulation processes of the radiator, as well as the composite fin arrangements with stress efficiency rates. The study examined the velocity path, pressure variations, and temperature distribution in the radiator setup. As found that nanoparticles and composite fins provide superior thermal heat rates and results. The combination of an aluminum radiator and composite fins in future models will support the control of cooling systems in automotive applications. The final investigation statement showed a 12% improvement with nanoparticles, where the velocity was 1.61 m/s and the radiator system’s pressure volume was 2.44 MPa. In the fin condition, the stress rate was 3.60 N/mm2.
MECHANICAL BEHAVIOUR OF CARBON AND JUTE FIBERS REINFORCED ALUMINIUM LAMINATES FABRICATED IN DIFFERENT STACKING SEQUENCES Suranaree Journal of Science and Technology, 2023
Bearing strength and failure modes analysis of carbon reinforced aluminium laminate Doctoral research in the area of fiber reinforced composites at Vel Tech University, Chennai., P. Sathyaseelan, S. Karthik, Assistant Professor in the Department of Mechanical Engineering at Veltech Rangarajan Dr.Sagunthala R&D Institute of Science, Technology, Chennai., Mathew Alphonse, assistant professor in the department of mechanical engineering at Vel Tech University, Chennai., R. Ramesh Kumar, Faculty of mechanical engineering at Vel Tech University, Chennai. International Journal of Innovative Technology and Exploring Engineering, 2019
Modeling and analysis of screw using finite element analysis International Journal of Mechanical and Production Engineering Research and Development, 2018
Design and analysis of damper spring and its structural components International Journal of Civil Engineering and Technology, 2017
Design and analysis of vibration and harshness control for automotive structures using finite element analysis International Journal of Civil Engineering and Technology, 2017
Manufacturing and force determination of composite disc brake International Journal of Mechanical Engineering and Technology, 2017
Design and thermal analysis of stirling engine using industrial applications of ceramic material International Journal of Mechanical Engineering and Technology, 2017
Design and analys of knuckle streering using finite element analysis International Journal of Mechanical Engineering and Technology, 2017
Shape modification of microcantilever beam for biosensing applications Research Journal of Pharmaceutical Biological and Chemical Sciences, 2016
