A direct chill (DC) casting is a continuous casting process widely used in different industries. The aim of the work is to investigate thermal and mechanical stress formed during the direct chill casting process by a numerical method. A commercial software ANSYS mechanical APDL is used for the simulation. A moving mesh technique is employed for the development of ingot during the solidification process. An element birth and death concept is used to find out the deformation in ingot. The verification of the results is done with the results found in literature and found a good agreement. The developed model has admirable ability to predict the thermal and mechanical stress formed in direct chill casting process.