Some defects

such as surface gas bubble and internal shrinkage hole in trial-production die casting Zn alloy faucet wrench were observed due to pouring-exhausting-flooding system designed by experience.So effects of structure and size design of pouring-exhausting-flooding system on filling and defects formation were analyzed based on wrench structure features and defects forming mechanism.Meanwhile

filling and defects formation in die casting were simulated by means of the Procast software.On the basis of simulated results

combining with die casting theory

design of pouring-exhausting-flooding system of the die casting die was optimized.The results indicate that surface gas bubble and internal shrinkage hole in the wrench can be greatly eliminated as a result of avoiding serious splash and eddy by adopting an expanding side runner with variable cross section and a wider ingate to obtain a desirable filling in cavity of wrench die with ratio of high length to width

meeting quality requirement for the castings.