The paper describes the design of carbon fiber-epoxy resin brake rotor for disk brake arrangement and analysis it using ANSYS. This design process is carried out by using computer-aided design (CAD) software. Furthermore, the analysis is performed by using ANSYS software. The main objective of the project is to design and analyze the thermal and structural stress distribution of brake rotor at the real-time condition during the braking process. The study of stress distribution in Brake disk while running condition is carried out for the carbon fiber material and it is compared with the existing one. The optimization is carried out to reduce the stress concentration and weight of the brake rotor which keeps the unsprung mass low thereby increasing the stability of the vehicle. The structural model of brake rotor is developed in CATIA software with the material of carbon fiber. In addition to this Silicon Carbide is added to increase the wear resistance of the brake rotor. The composite consists of mainly two-phase i.e. matrix and fiber. The major outcome of the paper is to study the different stress distribution in the brake disk using carbon fiber and compare with the conventional brake disk with the temperature, stress distribution, and weight. Fiber reinforced polymer composites have numerous preferences, for example, a generally minimal fort of creation, simple to create and better quality contrast than perfect polymer tars due with this reason fiber is used enormous usage in the material to strengthened.