Disc Brake is an essential Component of automotive braking system. Its generally subjected to high amount of temperature and pressure for continuous stopping of vehicles. The literature shows most of work is done on the structural strength and transient temperature impact on disc brake. No work is executed on crack development at high stress intensity point on the disc brake surface. 150cc Pulsar two-wheeler is considered for designing and analysis of the disc. 3D Modelling of the disc brake is done by 3D Modelling software Solidworks and All the design parameters are taken from the literature papers. Finite Element analysis software ANSYS workbench 15.0 is used for Structural, Thermal and Crack development analysis at actual working condition of the disc brake. Finite element analysis on the disc brake shows that, Crack initiation taken place at High intensity point on the crack surface and Crack Development will happen when J Integral value of the Simulation crosses the SIF of the Material. FEA simulation also show the rate at which crack develops and direction of crack Movement.

Keywords : Stress Intensity Factor(SIF), J-Integral(JINT), Finite element analysis (FEA), Meshing, Brake Pads, Brake Rotor.