I did Tiruvanamalai a month back and the roads have been relaid to a large extent. You have a few potholes here and there as hvkumar said. Read my exhaustive update on the Bangalore - Tiruvannamalai thread about a month or so back.
I wouldn't take the Salem route as Salem - Karur is being 4 laned and I had a horrible time even in the bus from Thanjavur to Bangalore a few weeks back. Krishnagiri - Salem is also being 4 laned but atleast one part is ok as of now.
Bangalore to Tvmalai is 4 hrs max nonstop, provided you leave early and escape the Bangalore - Hosur traffic. (200 kms)
Tiruvannamalai to Panruti is around 90 kms via Tirukoyyilur. probably 2 hours (not been on this route as yet. Planning to mid June)
Panruti - Kumbakonam - 100 kms or so. another 2 hrs.
So with stops and everything you could do it in 9 hrs or so. Approx distance 390 - 400 kms max.
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