A three dimensional finite element model is employed to simulate the cladding process of Ni-Cr-BSi coatings on 16MnR steel under different parameters including laser power, scanning speed and spot diameter.The temperature and residual stress distribution, the depth of the heat affected zone (HAZ) and the optimized parameters for laser cladding remanufacturing technology are obtained. The orthogonal experiment and intuitive analysis on the depth of the HAZ are performed to study the influence of different cladding parameters.A new criterion based on the ratio of the maximum tensile residual stress and fracture strength of the substrate is proposed for optimization of the remanufacturing parameters. The results show well agreement with that of the HAZ analysis.