Title: Design, exergy analysis and heat transfer investigation of a new automotive brake disc

Authors: Mohamed Ben Jamel Haddar; Ahmed Ghorbel; Fathi Djemal; Mohamed Haddar; Mounir Baccar

Addresses: Advanced Fluid Dynamics, Energetics and Environment, Sfax National School of Engineers, University of Sfax, Sfax, Tunisia ' Laboratory of Mechanics, Modelling and Production, National School of Engineering of Sfax, University of Sfax, Sfax, Tunisia; Higher Institute of Applied Sciences and Technology of Kairouan, University of Kairouan, Kairouan, Tunisia ' Laboratory of Mechanics, Modelling and Production, National School of Engineering of Sfax, University of Sfax, Sfax, Tunisia ' Laboratory of Mechanics, Modelling and Production, National School of Engineering of Sfax, University of Sfax, Sfax, Tunisia ' Advanced Fluid Dynamics, Energetics and Environment, Sfax National School of Engineers, University of Sfax, Sfax, Tunisia

Abstract: This study investigates the thermal behaviour of four brake disc geometries using computational fluid dynamics (CFD). A standard full rotor (SFR), a standard radial vane rotor (SRV-R), a circular pillar design (CP) and a novel Y-shaped disc with cooling fins are analysed under identical braking conditions. In addition to heat distribution and airflow characteristics examination, an exergy analysis is conducted to identify the most efficient configuration. Results indicate that the Y-shaped design delivers superior cooling with 20%-30% lower heat build-up and reduce exergy destruction, demonstrating its clear thermodynamic advantage for enhancing braking performance and safety.

Keywords: brake disc; exergy; heat transfer; standard full rotor; SFR; standard radial vane rotor; SRV-V; circular pillar; CP; Y-shaped disc.

DOI: 10.1504/IJEX.2026.154494

International Journal of Exergy, 2026 Vol.50 No.2, pp.95 - 106

Accepted: 16 Dec 2025
Published online: 30 Jun 2026 *

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