The impact resistance, friction resistance and wear resistance of semi-autogenous mill liners have long been a concern of major concentrators and mill manufacturers. The service life of the liner is closely related to its casting quality. Only by strictly controlling the quality from the source of its production, that is, the casting process, can its service life be guaranteed. To eliminate defects such as shrinkage hole and shrinkage porosity in the lining strips of large-scale semi-autogenous mill cylinders produced by a V-process foundry, ProCAST software was used to simulate the macroscopic casting process of the original foundry method, and the causes of shrinkage hole and shrinkage porosity defects were analysed. Then, the casting process of the lining plate was newly designed by using the independently developed “intelligent design of casting process (cast steel)” software. After simulation and production verification, the new casting process effectively eliminates the shrinkage hole and shrinkage porosity defects inside the lining plate, improving the casting quality and increasing the process yield from 65% to above 85%, with remarkable economic benefits.