Achieving multi-response optimization of control parameters for Wire-EDM on additive manufactured AlSi10Mg alloy using Taguchi-grey relational theory Murali Krishnan R, Rajesh Ranganathan, Saiyathibrahim A, Rajkumar Velu, Vijaykumar S Jatti, Dhanesh G Mohan, Praveenkumar Vijayakumar Engineering Research Express, 2025 The current research aims to optimize the multi-response during Wire Electrical Discharge Machining (Wire-EDM) of SLMed AlSi10Mg by using Taguchi integrated Grey Relational Analysis (GRA). Selective Laser Melting (SLM) is one of the most well-known and practical Additive Manufacturing (AM) methods, with the potential to replace many traditional production processes. The complex metallic support structures created during SLM require special attention as they are difficult to remove by hand. Therefore, this study performs post-processing using the Wire-EDM precision machining technique to evaluate the machinability of the SLMed AlSi10Mg as-built part. The multi-response optimization in this study aims to achieve the maximum material removal rate and the lowest surface roughness while considering four important influencing factors (pulse On time, pulse Off time, servo voltage, and wire feed rate) at four distinct levels. The Taguchi integrated Grey Relational Analysis (GRA) revealed that a pulse On time of 118 μs (Level 3), a pulse Off time of 44 μs (Level 1), a servo voltage of 60 V (Level 4), and a wire feed rate of 7 m s−1 (Level 4) are recommended to achieve optimal machining of SLMed AlSi10Mg. Furthermore, the derived optimization results were carefully verified through a confirmatory experiment, which showed a 38.57% improvement in multi-response characteristics compared to the initial Wire-EDM parameter settings. The methodology proposed in this work offers a standardized approach that has the potential to be implemented for the rapid and precise prediction and optimization of surface roughness, while achieving better material removal during Wire-EDM of SLMed AlSi10Mg.
Virtual registration of comminuted bone fracture and preoperative assessment of reconstructed bone model using the Procrustes algorithm based on CT dataset Senthilmurugan Arumugam, Rajesh Ranganathan, Venkatesh Kumar Narayanasamy Proceedings of the Institution of Mechanical Engineers Part H Journal of Engineering in Medicine, 2024 A research work was undergone in a virtual bone reduction process for reconstruction of the comminuted pelvic bone fracture using a CT scan dataset of patients. This includes segmentation, 3D model optimization and bone registration technique. The accuracy of the reconstructed bone model was validated using Finite Element Method. Analysed and applied various segmentation techniques to segregate the injured bone structure. The ICP (Iterative Closest Point), Procrustes algorithm and Canny edge detection algorithm were applied to understand the bone registration process for surgery in detail. The average RMS error, mean absolute distance, mean absolute deviation, and mean signed distance of the reconstructed bone model using proposed algorithms involving 10 patient datasets in a group were found to be 1.77, 1.48, 1.51 and −0.31 mm respectively. The calculated RMS error value proved minimal error in semi-automatic registration than other existing automatic registration techniques. Therefore, the proposed approach is suitable for virtual bone reduction for comminuted pelvic bone fracture. This method could also be implemented for various other bone fracture reconstruction requirements.
Design and development of customized finger prosthesis with novel mechanism using additive manufacturing Sivakumar Ganesan, Senthilmurugan Arumugam, Mohan Pushparaj, Rajesh Ranganathan Mechanical Properties and Characterization of Additively Manufactured Materials, 2023 The role of additive manufacturing (AM) in healthcare applications is increasing to develop prosthesis for congenital and accidental deformities. Amputation of finger could be because of either a traumatic injury or preplanned surgery to prevent spread of serious disease. Biomechanism of human fingers is more crucial and requires complex design structures to replicate its mechanical motion. The main focus of this work is to design and develop a customized functional prosthesis mimicking the characteristics of pinky finger. Methods AM was used to develop a customized functional prototype of a finger prosthesis with novel mechanism. A novel mechanism was developed to perform operations of the finger. The mechanism consists of three major parts, namely base, middle and tip. The base part has a socket to hold the prosthesis in position on the hands of the patient. Middle part was designed to connect base and tip parts of the finger prosthesis. A tip part at the end supports touching of the desired objects. Finally, a rigid connector part supports three major parts of the mechanism to remain connected through tendon and wrist of the patient. Design optimization was performed to decrease weight of the prosthesis. Acrylic material was used to manufacture the prototype in order to understand the outcome of desired biomechanism and further design improvements were made with the mechanism. Finally major parts of the finger were made with ABS material. Fused Deposition Method (FDM) technology was used to manufacture the finger prosthesis and indulge in post-processing to achieve the finished product. Conclusion A complete customized finger prosthesis with novel mechanism was developed using FDM technology. However, the developed prosthesis was customized based on the measurements taken from the patients and 3D scanning. Though the developed prosthesis requires further improvisation, it satisfied the mechanism. The replaced prosthesis did not serve the movement of a natural finger. Further, the proposed mechanism was not supposed to perform minor movements like a natural finger. The objective to serve as a finger prosthesis was achieved and the same procedure could be adapted to develop any finger prosthesis using 3D printing technology.
Design and development of customized elbow orthosis using additive manufacturing Sivakumar Ganesan, Rajesh Ranganathan Proceedings of the Institution of Mechanical Engineers Part L Journal of Materials Design and Applications, 2023 The orthosis is an assistive device to help people with disabilities. Orthosis, further known as braces, is used to support and modify the characteristics of human neuromuscular and musculoskeletal systems. In this study, elbow hyperextension is considered a significant cause of hand deformity. The elbow hyperextension occurs when the elbow joint in hand is being bend beyond its normal range of motion. Most commonly, orthosis was employed to treat the elbow hyperextension externally. In recent times, elbow orthosis design is customized ergonomically to fit a specific patient. The design is based on the customized profile of the human hand from the three-dimensional (3D) scanner. Sense 3D body scanner is used for scanning the human hand and 3D modeling of orthosis is done in SolidWorks. In order to reduce material consumption, topological optimization was performed. A developed novel mechanism was validated for failure analysis. The developed elbow orthosis is produced by additive manufacturing processes namely fused deposition modeling (FDM) and PolyJet technology. In FDM, acrylonitrile butadiene styrene material has been used whereas in the case of PolyJet printing, vero white material is used. The developed ergonomically designed orthosis can be worn for a long period of time without causing pain and therefore curing time is faster. A significant advantage of this proposed elbow orthosis is a self-operated novel mechanism.
EFFECT OF ALKALI TREATMENT ON MECHANICAL PROPERTIES AND MICROSTRUCTURAL ANALYSIS OF LUFFA CYLINDRICA AND SNAKE GRASS FIBER-REINFORCED EPOXY COMPOSITES M. SURIYAPRAKASH, R. RANGANATHAN, V. S. SREE BALAJI, M. NALLUSAMY Surface Review and Letters, 2023 This study investigates the mechanical properties of Luffa cylindrica and snake grass fiber composites prepared with different combinations of fiber and resin. Fibers are produced from natural sources having good mechanical properties and eco-friendly that can be used in various engineering applications such as automobile, aerospace and automotive industries. The Luffa cylindrica and snake grass fibers will be treated for 3[Formula: see text]h with alkali (NaOH) chemical treatment. The treated fibers are then developed as Laminate composites using compression molding technique. The composites have been made in five different compositions by varying the weight percentage (wt.%) of the chemically treated Luffa cylindrica and snake grass fibers (combination of maximum 30[Formula: see text]wt.%) mixed with epoxy resin and hardener (maximum of constant 70[Formula: see text]wt.%). Bonding between the fiber and matrix plays a vital role in influencing the mechanical characteristics of composites. The five samples have been prepared from the five different compositions and undergone various studies to find its mechanical properties such as ultimate tensile test (UTS), impact test, flexural test and water absorption test. It is found that the UTS and flexural strength have been considerably enhanced by sample 2 and impact strength has been notably increased by sample 3. The microstructure of tensile-tested specimen is observed by using the Scanning Electron Microscopy (SEM). It is reported that the better bonding between the fibers and matrix has been observed by SEM microstructural analysis.
Development of novel customized pressure distribution surface for reduction of pressure ulcers using additive manufacturing technology Sivasankar Arumugam, Rajesh Ranganathan Rapid Prototyping Journal, 2022 Purpose This research aims to focus on developing a customized support surface using additive manufacturing (AM) for effective pressure relief for patients who are in bed or wheelchair suffering from pressure ulcers (PU). Design/methodology/approach A novel customized support surface is developed using AM technology incorporated with magnetic levitation and ball and socket mechanisms. Magnetic levitation provides cushioning effect for the developed cushion to users who are sitting in a wheelchair and increases the rate of healing. The ball and socket mechanism provides the user body's self-adaptive mechanism and reduces shear and friction forces between the surfaces of the additive manufactured cushion and the human buttocks. Findings From the results of ISO 16480-6 biomechanical standardized tests, the additive manufactured support surface performed better than, or on par with, the most widely available commercial cushions. It is evident that the developed cushion’s peak pressure values are lower when compared with other cushions. The overall efficiency of the developed cushion was qualitatively reported; 67% of people felt it was excellent and 22% of people responded as good and 11% were satisfactory. Henceforth, the overall effectiveness of the developed support surface provides a better experience to the end-user in the view of PU reduction. Originality/value A developed additive manufactured customized support surface will be an alternative approach for the reduction of PU, and it overcomes the drawbacks faced by the currently available cushions.
Design and Development of a Customized Laparoscopic Forceps Handle Using Fused Deposition Modeling Journal of the Chinese Society of Mechanical Engineers Transactions of the Chinese Institute of Engineers Series C Chung Kuo Chi Hsueh Kung Ch Eng Hsuebo Pao, 2019
Influence of Geometry and Infill Density on the Mechanical Performance of Additively Manufactured Ti6Al4V Triply Periodic Minimal Surface Lattice Structures for Biomedical Implants RM Krishnan, R Ranganathan, A Saiyathibrahim Journal of Materials Engineering and Performance 35 (5), 4774-4796 , 2026 2026 Citations: 2
Human–machine interaction in virtual smart factory for additive manufacturing KS Mohanraj, R Ranganathan, S Sivasankari, S Suresh, AA Negemiya Smart Technologies and Digital Transformation in Additive Manufacturing, 155-174 , 2025 2025
Exploring the impact of surface modifications on the mechanical characteristics of acrylonitrile butadiene styrene parts manufactured using fused deposition modeling 3D printing R Karthikeyan, R Ranganathan, VS Sreebalaji, S Munusamy Journal of Materials Engineering and Performance 34 (5), 3811-3818 , 2025 2025 Citations: 3
Achieving multi-response optimization of control parameters for Wire-EDM on additive manufactured AlSi10Mg alloy using Taguchi-grey relational theory R Ranganathan, A Saiyathibrahim, R Velu, VS Jatti, DG Mohan, ... Engineering Research Express 7 (1), 015404 , 2025 2025 Citations: 18
Multi-response Optimisation of Wire-EDM for SLMed AlSi10Mg using Taguchi-Grey Relational Theory R Ranganathan, A Saiyathibrahim, R Velu, VS Jatti, DG Mohan 2024
Virtual registration of comminuted bone fracture and preoperative assessment of reconstructed bone model using the Procrustes algorithm based on CT dataset S Arumugam, R Ranganathan, VK Narayanasamy Proceedings of the Institution of Mechanical Engineers, Part H: Journal of … , 2024 2024 Citations: 3
Design and development of customized finger prosthesis with novel mechanism using additive manufacturing S Ganesan, S Arumugam, M Pushparaj, R Ranganathan Mechanical Properties and Characterization of Additively Manufactured … , 2023 2023
Design and development of customized elbow orthosis using additive manufacturing S Ganesan, R Ranganathan Proceedings of the Institution of Mechanical Engineers, Part L: Journal of … , 2023 2023 Citations: 5
EFFECT OF ALKALI TREATMENT ON MECHANICAL PROPERTIES AND MICROSTRUCTURAL ANALYSIS OF LUFFA CYLINDRICA AND SNAKE GRASS FIBER … M Suriyaprakash, R Ranganathan, VS Sree Balaji, M Nallusamy Surface Review and Letters 30 (03), 2350012 , 2023 2023 Citations: 9
Development of novel customized pressure distribution surface for reduction of pressure ulcers using additive manufacturing technology S Arumugam, R Ranganathan Rapid Prototyping Journal 28 (7), 1407-1421 , 2022 2022 Citations: 5
Need for customisation in preventing pressure ulcers for wheelchair patients-a load distribution approach S Arumugam, R Ranganathan, T Ravi International Journal of Biomedical Engineering and Technology 38 (1), 44-64 , 2022 2022 Citations: 7
Development of 3D Printed Smartphone-Based Multi-Purpose Fundus Camera (MultiScope) for Retinopathy of Prematurity A Pugalendhi, R Ranganathan Annals of Biomedical Engineering 49 (12), 3323-3338 , 2021 2021 Citations: 6
Examining the build properties of PolyJet printed multi-material parts in additive manufacturing A Pugalendhi, R Ranganathan Recent Advances in Manufacturing, Automation, Design and Energy Technologies … , 2021 2021 Citations: 6
A review of additive manufacturing applications in ophthalmology A Pugalendhi, R Ranganathan Proceedings of the Institution of Mechanical Engineers, Part H: Journal of … , 2021 2021 Citations: 13
3D printed patient-specific bone models for anatomy education from medical imaging A Pugalendhi, S Arumugam, R Ranganathan, S Ganesan J. Eng. Res, 1-12 , 2021 2021 Citations: 3
Husking and mechanical properties of ISAF N231/SAF N110 carbon black filled XNBR-ENR blend rubber compound for rice husk removal applications P Paramasivam, R Rathanasamy, R Ranganathan, SK Palaniappan, ... Materials Testing 63 (8), 783-787 , 2021 2021 Citations: 2
Spur gear mechanism for accurate angular indexing and locking of angular position by using additive manufacturing A Pugalendhi, R Ranganathan, C Vivek Machines, Mechanism and Robotics: Proceedings of iNaCoMM 2019, 105-117 , 2021 2021
of Angular Position by Using Additive A Pugalendhi, R Ranganathan, C Vivek Machines, Mechanism and Robotics: Proceedings of iNaCoMM 2019, 105 , 2021 2021
Development of customized support for the prevention of Pressure Ulcer (PU) using multi-materials printing S Arumugam, R Ranganathan, A Pugalendhi Journal of Physics: Conference Series 1969 (1), 012014 , 2021 2021 Citations: 4
Time of PolyJet Printed Parts Using Taguchi Method A Pugalendhi, R Ranganathan Advances in Materials Processing and Manufacturing Applications: Proceedings … , 2021 2021
MOST CITED SCHOLAR PUBLICATIONS
Responsiveness, the primary reason behind re-shoring manufacturing activities to the UK: An Indian industry perspective H Moradlou, C Backhouse, R Ranganathan International Journal of Physical Distribution & Logistics Management 47 (2 … , 2017 2017 Citations: 109
Selection of suitable additive manufacturing machine and materials through best–worst method (BWM) M Palanisamy, A Pugalendhi, R Ranganathan The International Journal of Advanced Manufacturing Technology 107 (5), 2345 … , 2020 2020 Citations: 66
Impact of process parameters on mechanical behaviour in multi-material jetting A Pugalendhi, R Ranganathan, S Ganesan Materials Today: Proceedings 46, 9139-9144 , 2021 2021 Citations: 56
Effect of process parameters on mechanical properties of VeroBlue material and their optimal selection in PolyJet technology A Pugalendhi, R Ranganathan, M Chandrasekaran The International Journal of Advanced Manufacturing Technology 108 (4), 1049 … , 2020 2020 Citations: 50
An efficient supplier selection model for hospital pharmacy through fuzzy AHP and fuzzy TOPSIS P Manivel, R Ranganathan International Journal of Services and Operations Management 33 (4), 468-493 , 2019 2019 Citations: 47
Effect of build orientation on the strength and cost of PolyJet 3D printed parts SC Das, R Ranganathan, M N Rapid Prototyping Journal 24 (5), 832-839 , 2018 2018 Citations: 42
Modelling and optimisation of Indian traditional agriculture supply chain to reduce post-harvest loss and CO2 emission M Chandrasekaran, R Ranganathan Industrial Management & Data Systems 117 (9), 1817-1841 , 2017 2017 Citations: 39
Review on parameters influencing the rice breakage and rubber roll wear in sheller P Prabhakaran, R Ranganathan, V Muthu Kumar, R Rajasekar, ... Archives of metallurgy and materials 62 (3) , 2017 2017 Citations: 30
Agility and supply chain uncertainty: a scenario planning perspective S Dani, R Ranganathan International Journal of Agile Systems and Management 3 (3-4), 178-191 , 2008 2008 Citations: 27
Genetic algorithm for optimisation of distribution system in a single stage supply chain network with fixed charges P Manimaran, V Selladurai, R Ranganathan, G Sasikumar International Journal of Industrial and Systems Engineering 7 (3), 292-316 , 2011 2011 Citations: 26
Prioritized ABC – FSN Analysis of Inventory Management in Private and Hospital Pharmacy Followed by Questionnaire RR Manivel P International Research Journal of Pharmacy 7 (12), 104 - 113 , 2016 2016 Citations: 24
Analysis of factors influencing AM application in food sector using ISM A Palaniappan, S Vinodh, R Ranganathan Journal of Modelling in Management 15 (3), 919-932 , 2020 2020 Citations: 20
3D printed patient specific models from medical imaging-a general workflow T Ravi, R Ranganathan, A Pugalendhi, S Arumugam Materials Today: Proceedings 22, 1237-1243 , 2020 2020 Citations: 19
Achieving multi-response optimization of control parameters for Wire-EDM on additive manufactured AlSi10Mg alloy using Taguchi-grey relational theory R Ranganathan, A Saiyathibrahim, R Velu, VS Jatti, DG Mohan, ... Engineering Research Express 7 (1), 015404 , 2025 2025 Citations: 18
Design and development of customized split insole using additive manufacturing technique RR Sivakumar Ganesan International Journal of Rapid Manufacturing , 2018 2018 Citations: 16
A review of additive manufacturing applications in ophthalmology A Pugalendhi, R Ranganathan Proceedings of the Institution of Mechanical Engineers, Part H: Journal of … , 2021 2021 Citations: 13
Design and development of model eye for retina laser by using additive manufacturing A Pugalendhi, R Ranganathan, N Venkatapathy, K Narendran, PK Shah Proceedings of the Institution of Mechanical Engineers, Part H: Journal of … , 2021 2021 Citations: 13
3D printed personalized orthotic inserts using photogrammetry and FDM technology T Ravi, R Ranganathan, SP Ramesh, DS Dandotiya Fused Deposition Modeling Based 3D Printing, 349-361 , 2021 2021 Citations: 11
Machine tool component manufacturing–a lean approach B John, V Selladurai, R Ranganathan International Journal of Services and Operations Management 12 (4), 405-430 , 2012 2012 Citations: 11
Design and Development of a prosthetic leg for an amputated peacock using additive manufacturing SA Rajesh Ranganathan, Pradeep Mohan S K, Arivazhagan Pugalendhi International Journal of Rapid Manufacturing , 2018 2018 Citations: 10
