The casting process design and simulation of a high-manganese steel roller were presented in this paper. The casting process design principle, process parameters, points of attention, and the simulation parameters were introduced. Huazhu CAE was used to simulate the casting process. The STL document used in Huazhu CAE was converted from the 3D moulding of the casting process using the Solidwork software. The simulation results and practical production showed that the casting process can reduce shrinkage defects of the casting. And practical production also showed that the produced rollers, according to the technique, met the quality demands, such as no crack, no misrun, etc, and they were successfully used at the thermal power plant.