Abstract: For large sized castings with a mass of ≥5 t, restricted by dimensions, structures and performance uniformity in casting production, comprehensive process control cannot be achieved merely by traditional empirical methods. Finite element simulation can couple casting physical models with process parameters to simulate the mold-filling and solidification of molten metal as well as the internal stress distribution of castings, predict casting defects, and provide a scientific basis for process optimization. Taking a 7 t moving cone of cone mantle as the research object, flow fields, temperature fields and stress fields simulations were carried out combined with conventional gating riser design. The molten steel filling behavior, temperature field distribution and mold cavity impact effect under different pouring processes were analyzed. The results show that it is feasible to use the riser as a pouring gate. The segmented reducing necked down (RND) riser with a diameter to height ratio of 1∶1.5 can effectively reduce the impact of molten steel on mold cavity walls. Production verification demonstrates that the mass of the segmented RND riser is approximately 1/3 of that of the conventional gating riser system, and the cavity impact is reduced to about 10% of the traditional process. The technology mitigates slag hole defects and improves casting quality.