Hybrid ANOVA-ANN modeling and optimization of pulsed wave fiber laser microcutting parameters for machining Ni-Cr-Mo superalloy Kulothungan S, Poovazhagan Lakshmanan, Elamvazhudi B, Sarangapani Palani Physica Scripta, 2026 A non-conventional form of versatile machining process, particularly for machining hard and lightweight material is pulsed wave fiber laser micromachining (FLMM). In present work, pulse mode fiber laser machine was used to cut micro hexagonal profiles on Ni-Mo-Cr superalloy considering laser power, scanning speed, pulse frequency and number of passes as input parameters also analyses the output responses such as Kerf Width (KW), Heat Affected Zone (HAZ), Surface Roughness (Ra) and Material Removal Rate (MRR). Multi-objective optimization was performed through ANOVA and Artificial Neural Network (ANN). The 3D surface roughness analyser is used to check machined micro-hexagonal profiles. An MRR of 0.0959 mm 3 /s, kerf width of 24.7 mm, HAZ of 26.1 mm, and surface roughness of 0.084 mm were achieved at the optimal machining conditions. ANN model is developed to validate experimental findings and effectively used to predict the output responses. This work demonstrates the effectiveness of pulsed mode fiber laser micromachining of Ni-Mo-Cr superalloys with useful insights for aerospace, medical and microelectronic sectors.
Nanoclay influence on hygrothermal aging of corn husk–glass fiber hybrid composites Elamvazhudi Balasubramanian, Kulothungan Subramaniyan, Sathish Kumar Sankar, Nivethan Pazhani Journal of Reinforced Plastics and Composites, 2026 This work investigates the hygrothermal aging behavior of sustainable hybrid composites composed of corn husk, E-glass reinforcement, and epoxy matrix modified with organo-montmorillonite nanoclay (0–2 wt.%). Natural fibers reinforced hybrid composites were exposed to acidic, neutral, and seawater conditions for 60 days, to assess their environmental endurance. Natural fibers were incorporated in various forms included sheet, powder, and fibers. The research reveals the effect of incorporating nanoclay into the epoxy on hygrothermal aging of hybrid composites. Nanoclay additions into epoxy considerably reduced the moisture absorption percentage and decelerating mechanical properties deterioration rate. The sheet-based reinforced composites demonstrated greater long-term retention in aggressive conditions and fiber based composites offered higher initial strength. The study tackles important issues in the durability of natural fiber composites while advancing the value adding of agricultural waste. This work provides tensile properties decay models which offers practical guidance for designing sustainable composites for chemical, marine, and construction applications. In addition, this work provides open avenues for future research on machine learning models to predict durability performance under various environmental conditions.
Design sustainability of rollover protective structure in tractors Sakthivel Murugesan, Elamvazhudi Balasubramaniyan, Kulothungan Subramaniyan Turkish Journal of Engineering, 2025 TRollover Protective Structure (ROPS) design is becoming more important in tractors. Static analysis in accordance with the SAE J2194 standard is necessary for the designing ROPS prototypes that maximize safety while minimizing environmental impact. Using renewable and recyclable materials, energy-efficient production techniques, and sound design concepts to increase lifetime and durability are important tactics. In order to promote cradle-to-cradle design principles, the lifecycle assessment approach is utilized to examine environmental implications from material extraction to end-of-life disposal. The study shows how sustainable ROPS can be achieved by maximizing material consumption, putting modular designs into practice, and making sure that regulations are followed. To promote economic and social sustainability, factors like worker safety, local production, and recyclability are also taken into account. This analysis is a framework for designing ROPS that not only ensure operator safety but also contribute to broader sustainability goals, supporting a more sustainable agricultural sector. In this study, static load analysis on ROPS frame with different cross sections and loading conditions was performed using Finite Element Analysis (FEA). Three different cross sections were investigated: square, circular, and hollow circular. The produced stress, strain, and deformations under combined loading circumstances can be used to assess ROPS performance. The post-processing results reveal that the material qualities, shape, and loading conditions have a direct impact on the static load behaviour of ROPS. In comparison to other cross sections, the circular cross section has a high load bearing capacity and minimum deformation
Finite Element Failure Analysis on Carbon Glass Fiber Reinforced Polymer Laminates Elamvazhudi B, Arul Karthikeyan O, Dhinagaran S, Kathiravan E, Navinkumar S Turkish Journal of Engineering, 2025 This research focuses on comprehensive analysis on investigating the interlaminar fracture toughness and displacement behaviour of carbon and glass fiber reinforced hybrid polymer composites utilizing epoxy matrices. Delamination is the separation of layers within composite materials and interlaminar fracture toughness are an essential quality of measures that indicates the ability of a material to resist delamination. Predicting and preventing the failure of hybrid composites requires an understanding of their interlaminar fracture toughness values. Since delamination is a common failure mode of composite materials, it strongly affects the mechanical properties and load carrying ability of the structure. Such that assessing its interlaminar fracture toughness allows engineers to anticipate potential points of weakness, and prevent these areas from becoming problematic through any number of techniques designed to combat delamination. In hybrid composites, the capacity for energy dissipation and fracture in the matrix must be well evidenced before predicting structural integrity. This paper applies ANSYS simulation to model and evaluate the effects of five combinations of hybrid laminates, on both fracture toughness and displacement characteristics, to prove stress mitigation. The specific area that was researched involved fibre stacking sequences, fibre orientations, fibre types and thickness of lamina in an attempt to analyse the absorbent impact toughness of the different laminates. The parameters of interest are examined to not only determine the level of the interlaminar fracture toughness but also analyze the structure’s displacement fields. The results will benefit the field of composite mechanics in gaining a better understanding of composite designs for the integration of composite structures into new generations of multipurpose and high fracture resisting materials for practical applications in engineering.
Low-velocity impact and compression after impact behaviour of nanoparticles modified polymer composites B Elamvazhudi, S Gopalakannan Journal of Reinforced Plastics and Composites, 2024 Optimizing the impact properties of polymer composites is essential in aircraft industries. Hybridization of fibres is one of the efficient methods to enhance the impact properties of polymer composites. Dispersion of nanoparticles into epoxy resin improves the toughness of composites. This study examines the low-velocity impact (LVI) behaviour of hybrid epoxy-based carbon/glass fibre-reinforced laminates. Initially, the epoxy resin was modified with 0, 0.5, 1, 1.5, and 2 wt% of nanoclay and TiO2 nanoparticles using mechanical stirring followed by an ultrasonication method. To investigate the influence of stacking sequences, laminates were fabricated with (90 G/0 G/90 C)S, (90 G/0 C/90 G)S, and (90 C/0 G/90 G)S. The samples used for this study are six-ply symmetric laminates. Laminates were impacted with different impact energies between 30 and 80 J with an impact velocity of 7 m/s to generate damages. The residual strength of damaged specimens is determined using compression after the impact test. The order of stacking, fibre orientation, and the presence of nanoparticles all have a significant impact on the residual strength of laminates. By using C-scan images, layer-wise damage mechanisms were identified. The specimen with (90 C/0 G/90 G)S sequence has very high damage resistance compared to other laminates.
Surveillance Robots for Industry 4.0 C. Manimaran, B. Elamvazhudi, S. Kulothungan, V. Velmurugan 2024 3rd International Conference on Smart Technologies and Systems for Next Generation Computing Icstsn 2024, 2024 Nowadays, robots play an important part in our daily lives, decreasing human effort and error. Robots can be operated manually and automatically based on the requirement. This work's primary goal is to build and create a new robot that can conduct domestic surveillance. This robot can move around the area, gather information from the surrounding environment both visual and auditory and relay it to the user. The Internet of Things (IoT) enables control of the robot from a laptop or smartphone, and the wireless camera allows for daytime and nighttime live video streaming. Robot uses an Arduino microcontroller, an ultrasonic sensor, and an infrared sensor to gather data and transmit it to the microcontroller, which then regulates the robot's actions. Using object and motion detection, the user can identify the presence of people and objects in addition to the live streamed video output. This information provides a reliable surveillance activities. Further, this work may be applicable in defence areas to provide secret surveillance.
Real-time Tool Defect Detection Systems V. Velmurugan, B. Elamvazhudi, S. Kulothungan, C. Mamimaran 2024 3rd International Conference on Smart Technologies and Systems for Next Generation Computing Icstsn 2024, 2024 To support the competition and to produce industrial economically, it seems mostly that manufacturing systems must exhibit a high level of disgruntlement in their operation. Hence, to create such flexibility and thereby develop a Flexible Manufacturing System (FMS), it is necessary to reduce the human intervention in production. Flexibility in manufacturing can be understood and applicable through various standards & interpretations. In this work, the defects in the tools will be analyzed using image processing tools could exploit defects in the tool at a flexible manufacturing environment. Information from the installed sensors on vibration, acoustic emissions, spindle speed and cutting force in machine can be employed together to infer indirectly about tool flaws; portions or position referenced for correspondence mapping thus locating areas of interest. This information is primarily obtained through sensors, and upon processing this data it gives us some insight as to how the tool functions abnormally or where potential defects may be. A more direct approach is the non-contact cutting tool monitoring especially that which typically relies on vision images using optical inspection. This is because using this method, tool defects can be accurately described by size and position. It is possible to use digital image processing technologies to enhance the precision of the inspection and identification of the cutting tool’s condition. Besides making the methodology less rigid, it improves the reliability of cutting tool damage, workpiece defects, and tool positioning. In this case, the inspection process is aided by the DIP in providing extensive visual information concerning the condition of the tool. When it comes to this technology method, real-time control and quick decisions are provided and the dependence on people is significantly reduced, increasing versatility and manufacturing system performance. Therefore, the development of competitive and genuinely versatile production settings entails the incorporation of such advanced monitoring approaches.
