At the time of braking operation, the brake disc undergoes severe wear and high frictional temperatures. The main challenge lies in determining the ways heat is generated and distributed between the two components that are in contact. This study aims to investigate the temperature, stresses, and deformation that occur in the brake disc at the time of brake is applied. In this study, modifications are required: geometric modification of the disc brake and the use of cost-effective materials. In this work, the analysis of disc brakes is done with material (GCI) used for vented without holes (Base Model), Vented with holes (MM1), and holes with grooves (MM2). This study initially involved designing and calculating the brake force, brake torque, and heat generation. Then a 3D brake disc model was created using fusion software, and the performance of the brake disc was analysed using FEA software. It is found that MM1 provides better results in structural analysis (stress and deformation), and for thermal analysis, MM2 gives better results (temperature distribution). Then increase the speed of the disc to 100–160 km/h. The MM1 gives better results as compared to MM2.