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Based on the principle of one dimensional flow and heat transfer, the law of temperature attenuation along the path was acquired by solving the one-dimensional coupled heat conduction and convection equation with harmonic method. Then the law of rheological resistance increasing along the path was obtained. Meanwhile, the law of pressure attenuation along the path was solved. Finally, the prediction model of rheological filling ability for aluminum alloy in molten metal die forging was established by combining the stopping rheological mechanism and conditions of alloy melt. Furthermore, the model covered t he process parameters of molten metal die forging, material property parameters and mold structure structure parameters, and it was suitable for generalized semi-solid ally melt below liquidus temperature. The validity of theoretical model was verified by the length of Archimedes spiral sample of 6066 aluminium alloy by molten metal die forging. The resutls showed that the maximun relative deviation between the calculated results and the experimental results was only 8.2%. Compared with the exisying fillinf ability model, the rheological filling distance model in this paper has some progress in the prediciton accuracy and application scope. [ABSTRACT FROM AUTHOR]