Thermal Management of Automotive Brake Discs: A Computational Fluid Dynamic Approach to Aerodynamic Cooling

ABSTRACT Thermal management of automotive brake discs is critical, as excessive heat generation can degrade braking performance and reduce component lifespan. In this study, computational fluid dynamics (CFD) is used to evaluate the aerodynamic cooling performance of four disc configurations: standard full rotor (SFR), diamonds and tear drop pillars (DTDP), X‐shaped fins (X), and a novel Y‐shaped fin design (Λ). The analysis examines airflow behavior and heat dissipation through velocity, pressure, and temperature fields. Among the designs, the Λ configuration demonstrates the most effective cooling, achieving a maximum air velocity of 14.16 m.s − ¹, 33% higher than DTDP, and a mass flow rate of 0.525 g.s − ¹, 11% higher than DTDP and 50% higher than X. Correspondingly, temperature distributions indicate reduced hot spots and improved thermal uniformity. The average heat transfer coefficient (HTC) for Λ is 21 W.m − ².K − ¹, reflecting a 24% improvement over SFR and 7% over DTDP, while the total dissipated heat (TDH) reaches approximately 1750 W, 59% higher than SFR, 35% higher than X, and showing a marginal improvement over DTDP. These findings confirm that the Λ‐shaped fin design substantially enhances convective cooling, positioning it as a promising solution for next‐generation brake disc thermal management.