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The induction hardening and self-tempering of the axle casing ends were investigated. An inductor structure with speci- fied heating conductors for the filleted corners was developed and improved using finite element analysis. Process parameters were opti- mized after four rounds of experiment, and deformation tests manifested that the case hardening depth should be below 6mm in order to balance the deformation and the strength. A corresponding self-tempering process was applied to get the ideal mechanical property instead of furnace tempering. With a 4-5 mm case hardening depth and a final surface hardness of 52-58 HCR, the road test showed that the mileage was more than 80,000 km for average road condition and 30,000 km for off road condition.