Dr. Rahul Yadav is an Assistant Professor in the Department of Mechanical Engineering at IIT Madras. His research combines experiments with computational modelling and simulation to tackle key challenges in subtractive manufacturing, with a focus on deformation physics, multiscale sustainable machining, surface integrity, and functional Surface Engineering for high-performance advanced engineering materials.
Prior to joining IIT Madras, he worked as an Associate Researcher on soft magnetic laminates cutting and simulation at the Future Electrical Machine Manufacturing (FEMM) Hub, University of Sheffield, United Kingdom, in collaboration with the Advanced Manufacturing Research Centre and other academic partners. He also served as an Associate Researcher at Cardiff University, where he contributed to AFM-based nano-component fabrication using feedback-controlled systems, along with particle-based simulation approaches for correcting elastic deflection errors.
Dr. Yadav obtained his PhD from IIT Kharagpur, where his research was on precision micro-scale material removal via ultrasonic-assisted pre-conditioning and multiscale modelling. This work resulted in a novel setup design, a patent, and several high-quality publications.
Multi-Scale Subtractive Manufacturing and Multi-Physics Process Modelling
Physics-Based Modelling of Deformation Mechanics in Microstructure-Sensitive Engineering Materials.
Multi-Energy Field Assisted Plastic Deformation Processes.
Functional Surface Engineering.
Awarded Best Technical Speaker at the International Conference on Industrial Engineering and Applications (Europe), Milan, Italy, January 2026.
Recipient of the Best Paper Award at the AIMTDR Conference on Manufacturing Technology, Design and Research, 2018.
Yadav R, Jewell G. W, Jones L, Ghadbeigi H, (2026). Coupled mechanical-magnetic analysis of cut-edge damage in thin sheet electrical steels. International Journal of Mechanical Sciences, 314, 111375. https://doi.org/10.1016/j.ijmecsci.2026.111375.
Yadav R, Chakladar N.D, Paul S, (2024). Tailoring of residual stress by ultrasonic vibration-assisted abrasive peening in liquid cavitation of metallic alloys. International Journal of Machine Tools and Manufacture. 194, 104100 https://doi.org/10.1016/j.ijmachtools.2023.104100.
Yadav R, Sharma A, Kulasegaram S, Alimohammadi S, Read D, Brousseau Emmanuel, (2024). Application of Mesh-free and Finite Element Methods in Modelling Nano-Scale Material Removal from Copper Substrates: A Computational Approach. International Journal of Solids and Structure. 194, 104100. https://doi.org/10.1016/j.ijsolstr.2024.112891
Yadav R, Kumar M, Chakladar, N. D, Sidpara A. M, Paul S, (2024). Evaluation of tool wear during micro- milling of ultrasonically assisted abrasive peened Ti-6Al-4V. Wear. 552-553, 205450. https://doi.org/10.1016/j.wear.2024.205450.
Yadav R, Kumar M, Chakladar, N. D, Sidpara A. M, Paul S, (2023). Effect of pre-stress on surface integrity in micro milling : Modelling and experimentation. Journal of Manufacturing Processes. 102, 564–578. https://doi.org/10.1016/j.jmapro.2023.07.073.
Yadav, R, Chakladar, N.D., Paul, S., (2022). Micro-milling of Ti-6Al-4V with controlled burr formation. International Journal of Mechanical Sciences. 231, 107582. https://doi.org/10.1016/j.ijmecsci.2022.107582.
Yadav, R., Chakladar, N.D., Paul, S. Ultrasonic-assisted Abrasive Peening System. Patent No.: 568737 (India). Date of grant: 16 July 2025.
