Computer simulation of induction heat treating processes is relatively widespread within the industry. The bulk of the simulation studies considered coupling two of the multiple phenomena that occur during the process: 1) the electromagnetic and thermal process, and 2) the metallurgical and thermal-stress process. Recent studies have incorporated more of the mutually coupled phenomena into the simulation process. In these studies, electromagnetic, thermal, metallurgical, stress and shape change were coupled together using multiple programs. These studies enhanced our capabilities to predict the actual part performance of induction hardening process. This paper describes a study of a complex induction hardening process of a full-float truck axle. The process includes a dwell heating of the flange and a scan hardening of the shaft and spline. Computer simulation of electromagnetic and thermal processes was made using Flux software. The power densities from Flux are then exported and mapped into the DANTE for thermal, metallurgical, stress and distortion simulation. The study is based upon component test data from Dana Corporation. INTRODUCTION It is well known that changes in thermal distributions throughout an induction hardening process create complex layers of stresses in the component. Both residual stresses and mechanical properties of hardened pattern have significant impact on service performance of the heated treated parts. The induction hardening of steel components is a high nonlinear transient process, which is not intuitively understandable in general. With the development of FEA modelling capability in the past couple decades, both electro-magnetic and thermal stress analyses of the induction hardening have become more mature, and they have been successfully applied to understand and solve industrial problems [1]. The mechanical properties and residual stresses can be predicted by finite element analysis, which will further be used to analyse the mode and location of fatigue failures [2-5]. The component geometry and process can be also optimised to reduce part weight, manufacturing cost, and optimum performance. When considering heat treatment of steel components, induction hardening is a common processing method due to its fast heating times, high efficiency, and ability to heat locally. However, predicting the final properties of a component after induction processing adds another layer of complexity. Not only temperature and structure have to be considered, but also electromagnetism. When hardening of steel, the magnetic properties change throughout the process, affecting the thermal distribution and structure. Coupling these various phenomena to