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Within the advances in Computer Fluid Dynamics algorithms and High Performance Computing, large clusters become available at low costs allowing virtual simulations that were not possible some years ago at reasonable costs and time. This work uses intensively this condition and applies these advances on brake system optimization. The methodology developed in the present work verifies the best angular position for caliper inside the wheel to reduce the rotor temperature during braking process such as downhill procedure. Thus, this method is applied to a mini-VAN vehicle, where the best position is found, based on two design parameters: rotor temperature and convection heat transfer coefficient. This study shows that the most suitable position for initial selection is the first one.

Environment concerns lead the automakers to invest resources and put research in engine downsize to reduce carbon emission. Turbo charge is a possibility due to its fuel consumption and emission reduction without compromise the performance. Nowadays, it is becoming common observe high performance small cars due to high torque and power available. In consequence, brake system need to dissipate more kinetic energy without adding mass or costs. Modern passenger cars require a high-speed brake system. To achieve proper brake system cooling, the rotor must be ventilated and designed to optimize the energy dissipated, which is generated by friction between pad and disk. Some approaches consider the rotor as a centrifugal air pump and the design rule is to improve the airflow inside the vanes. The approach considering a brake rotor similar to centrifugal air pump rotor may be considered as limited approach, once it simplifies the heat transfer phenomena inside chamber.

The brake system is of vital importance when engineering a new vehicle due to its implication with both safety and overall performance. One of the main questions that arise when designing the brake system, not only in terms of performance but also in efficiency and fuel economy is how to make a better brake rotor. When designing the brake rotor, thinking about mass reduction and design optimization is a desire not only for high-performance motorsport, but for daily user applications. The impact on the vehicle performance would lead to improved fuel economy and braking safety. In this work, we propose to exploit some characteristics that can optimize the rotor design to achieve better performance, compared to a baseline design proposed. Some constructive characteristics are kept constant such as the rotor diameter and thickness. The use of computational fluid dynamics (CFD) simulations is considered in this study as a benchmark to future physical prototypes experiments.