Cast aluminum rotor is one of the main components of the AC asynchronous motor and its quality has a great influence on the starting performance and oper-ating performance of the motor.The forming process of the cast aluminum rotor is simulated by the mold flow while the easy-trapped-gas point is judged and the exhaust groove is added to the position.The test and verification results show that the scheme effectively improves the quality of the cast aluminum rotor.