In this study, a gearbox produced by high-pressure die casting method is analyzed depending on different thermal and dynamic parameters by Vulcan and Flow3D simulation soft wares. In the simulations, die temperature is taken as 423 and 573 K, and casting temperature is taken as 953 and 1053K. In addition, Injection’s second phase velocity is determined 1, 3 and 5 m/s respectively. Moreover,
... [Show full abstract] filling gate and biscuit are determined as the start point of second phase. 48 simulations are totally performed using those parameters in those soft wares. Simulation outcomes are studied in terms of porosity as well as the effects of different injection parameters on the product porosity. Optimal casting parameters for the gearbox given its details in the material and methods section of the study are also presented. When all the experimental parameters are taken into consideration, optimal conditions are determined as such that Filling gate is for the second phase start point, second phase velocity is 2 m/s, casting temperature is 1053K and die temperature is 573K. Porosity amount is 2.72% for Vulcan and 3.24% for Flow3D. According to the obtained results, porosity amount is decreased 27% in the ideal conditions