Abstract: According to the structural characteristics, chemical composition and customer requirements of the coal mill roller sleeve substrate, a set of scientific and reasonable casting process is developed. With the help of casting simulation software, a comprehensive optimization analysis of the designed casting process is conducted to verify the feasibility in the production process. In order to ensure the smooth production process, countermeasures are predicted and formulated in advance so as to solve a series of quality problems that may occur in the production process of the casting, and to ensure that the casting performance fully meet the standard requirements of customers. The successful production of the coal grinding roller sleeve has laid the foundation stone for the follow-up production of such products.