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In this paper the authors report on a development at Bharat Forge where CAE tools are an integral part of the new physical test laboratory. The paper will show how CAE can be used to model the physical test process and create its own “virtual test” process. By using these tools in parallel and by validating the virtual process at each stage of the test process, confidence is gained in the virtual process. The goal is to integrate the virtual test process into the component design process to establish an early validation of the component prior to finalizing the dies and forging the component.