Strategy and function of a new developed FEM code COSMAP(COmputer Simulation of MAterial Process) for surface hardening during of thermo-mechanical processing, including heat treatment, carbonizing and nitriding and induction heat treatment, is briefly introduced in this paper. The simulation code is developed based on the metallo-thermo-mechanical theory considering the coupled equations of magnetic or electrical field, diffusion, heat conduction, inelastic stresses and kinetics of phase transformation. Some examples of simulation and the experimental verification for induction heat treatment, carbonized quenching, carbonized- nitrided-quenching process of a cylinder and ring as well as a gear are illustrated, and comparison of the simulated values of distortion, residual stresses and profile of induced phases with the experimental data is made with some discussions.