Disc brakes play a crucial role in modern vehicles by providing reliable and efficient stopping power through the friction between brake pads and rotating discs, ensuring effective deceleration and enhanced safety compared to traditional drum brakes. Additionally, disc brakes are easier to maintain, provide better responsiveness, and contribute to enhanced overall safety on the road. Brake discs are primarily constructed using grey cast iron and aluminum alloy are chosen for their commendable metallurgical stability, ease of manufacture, and economic viability. Grey cast iron and Al 6061 alloys are most favored for disc brake construction due to their commendable heat dissipation, wear resistance, and cost-effectiveness, making them ideal material for providing reliable and durable braking performance in various automotive applications. In the present work, a theoretical model of disc brake is created utilizing ABAQUS software, employing the Finite Element Analysis methodology for simulation and analysis purposes. ABAQUS offers a broad spectrum of multi-physics capabilities, adding versatility to its utility. The primary objectives of our study include analyzing the deformation behavior of these alloys under the following conditions: (i) Mechanical loading, (ii) Mechanical and thermal loading, (iii) Mechanical loading on a disc brake with groove, and (iv) Mechanical and thermal loading on a disc brake with groove. Through the application of ABAQUS, the research strives to assess the Von Mises stress distribution within the disc brake under different conditions, offering valuable perspectives on its structural performance and identifying potential avenues for improvement.