The ProCAST software was used to simulate the filling and solidification process of alloy wheels with complex wheel faces

and occurrence of the defects such as porosity

shrinkage porosity and shrinkage cavity was predicted and the origination of defects was analyzed.The simulated results reveal that when the initial lift velocity of metal liquid is reduced to 65 mm/s

porosity defects near the casting gate are relieved obviously.In addition

by adjusting the water flow velocity of the side mold water cooling system to 0.75 m/s and establishing the feeding channel on both sides of the spokes

the area of hot spot at the connection between the spoke and the rim is reduced and the defects are eliminated.The optimization scheme was adopted for producing trial-wheel.The results reveal that wheel surface exhibits clear with good mechanical properties and absence of significant defects

meeting the standard requirements.