One of the most important safety features of a car is the brake system. The rotor will experience significant loads throughout the braking process, which might lead to seals, brake fluid warming, and surface cracking, among other problems. Thus, lowering the brake rotor's surface temperature is one of the braking system's primary functions. One of the main factors in a lot of accidents has been brake failure, particularly on two-wheelers. The disc finally fractures owing to the excessive strains placed on it by the forced braking. This demonstrates that inappropriate materials and designs were used while examining the disc under various circumstances. The research discusses the different designs, such as the braking rotor with a slotted disc and holes and a normal disc. This project's primary goal is to suggest a new automobile brake disc rotor design for the BAJAJ PULSAR 150 that will maximise heat dissipation while reducing overall deformation. SOLIDWORKS software is used in the design of the vented disc (existing design) and the slotted with regular holes (proposed design). Grey cast iron, ALSIC, Ti6AL4V, AISI 6150, and EN8 are among the materials used in the static structural and thermal analysis of the brake disc rotor. ANSYS 18.0 is a specialised finite element package used to calculate the von Misses stresses, shear stress, strain, deformation, and total heat flux. In the disc brake profile all around. The optimal brake disc rotor design and material should be recommended based on the amount of strain deformation, shear stress, von Misses stresses, and total heat flow.

One of the most important safety features of a car is the brake system.