The substitution of die casting magnesium alloy for aluminum alloy in wheel products and its measures were analyzed by taking transmission pulley as a sample.Based on the analysis of service life and failure conditions

the structure of magnesium alloy transmission pulley was redesigned by the stress analysis of the original structure and topologic optimization analysis.The results reveal that service stress of the optimized magnesium alloy transmission pulley is decreased from 40.5MPa to 24.7MPa

greatly lower than ultimate fatigue strength.In addition

the absence of die casting defects in the pulley can be observed due to the realization of sequential solidification during filling process.Compared with those of aluminum alloy ones

the weight and cost of magnesium alloy transmission pulley are decreased by 43.8% and by 34.5%

respectively.