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To investigate the infiltration mechanism of material liquid and the expansion and deformation characteristics of tobacco leaves in the casing process, a mathematical model of heat and mass transfer in the process of tobacco leaf casing based on the continuity theory and elastic theory of porous media is built. COMSOL software enables the realization of multi-physical field coupling in the process of casing. An analysis is made of the changes and the influences of temperature, material liquid infiltration rate as well as the expansion and deformation of tobacco leaves in the casing process. The results show: COMSOL software simulating the casing process of tobacco leaves, the peak temperature of leaves is 49.25 °C, the optimal casing environment temperature 65 °C, the final infiltration rate of material liquid 19. 85%, and the final leaf expansion rate 8.6%; the temperature change and material liquid infiltration of tobacco leaves mainly start when the material liquid are beaten onto the leaves; the moisture stress generated by the diffusion of the liquid inside the blade is significantly greater than the thermal stress generated by the temperature change, indicating that the diifusion of the liquid exerts a greater impact than the temperature on the expansion and deformation of the tobacco leaves; the maximum equivalent stress of tobacco leaves occurs at about 15 s after the casing begins, and in the part beaten by the liquid, revealing the expansion and deformation enlarge the tobacco leaf skeleton and the diifusion channel of liquid as well. The expansion and deformation during the tobacco leaf casing process positively affect the diifusion of material liquid, and the distribution of material liquid insiie tobacco leaves is the main factor which influences the uniform casing. This study optimizes the tobacco leaf casing process and provides a solid theoretical basis for digital production of cigarettes. [ABSTRACT FROM AUTHOR]