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A comprehensive review of the thermal response of disc brake system has been made. Extensive research has been carried out on the operating problems, the material for the rotor, design of the rotor and the braking conditions of the disc brake systems and numerous methods of improvement are proposed. Various ventilation patterns have been studied in order to enhance thermal efficiency, and structural performance reductions have been found in most cases. Which creates need for the design of discs with optimal thermal and structural characteristics, so that disc brake performance can be enhanced without compromising in strength and other parameters of the disc brake system. It is expected that this exhaustive and comprehensive review will help the research fraternity in identifying the research gaps for their future work. The prime purpose of this paper is to provide an exhaustive overview of developments going on in this field. The proposed research work attempts to develop and modify the system which uses the effective method to minimise the temperature and weight of disc brake rotor by thermo-mechanical analysis to optimise the performance of Disc brake. The proposed design of disc brake offers a promising solution to improve the braking efficiency by 15%and overall reduction in weight of disc brake by 10%.

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