The design of the casting process was obtained by traditional casting design method. The process was composed of the choice of the casting position and the determination of casting parameters and the design of the gating system. According to the structural characteristics of sheave and quality requirements, the sheave hub and rim were poured separately. In order to achieve progressive solidification, two insulated risers were laid on the top of the wheel, and some risers were placed on the top of the hot spot in the rim and cold iron was introduced near by the thick part of the wheel hub. Three-dimensional model of the casting was generated and the solidification process of the sheave was simulated by View Cast. The results showed that the hot spot areas in the rim and thick part of the wheel hub have frozen finally, and the shrinkage formed in those areas. According to the simulation results and analysis, the casting process program was optimized by increasing the size of riser and the thickness of cold iron. After simulated once again, the defects were transferred to risers. The defects were eliminated to the greatest extent and the progressive solidification was achieved. So the reasonable program of the casting process was obtained.