The traditional design approach of grabs and other bulk handling equipment consists of manufacturing and testing physical prototypes. A novel design approach is to use a co-simulation of MultiBody Dynamics (MBD) and Discrete Element Method (DEM), in which the virtual prototype of a new concept interacts with bulk solids. Therefore, this study develops and validates a full-scale co-simulation that models the grabbing process of cohesive and stress-history dependent iron ore. First, by executing in-situ measurements during the unloading of a vessel, grab-relevant bulk properties of the cargo, such as penetration resistance, are determined. Second, full-scale grabbing experiments are conducted in the cargo hold, which allows the process to be recorded in realistic operational conditions. Third, full-scale co-simulation is set up using the material model that has been calibrated based on an elasto-plastic adhesive contact model. Fourth, the co-simulation is validated by comparing its predictions to experimental data from various aspects, such as the force in cables and the torque in winches. The validated co-simulation proves that the stress-dependent behaviour of cohesive cargo as it interacts with the grab could be captured successfully. Valuable information such as a grab's kinematics and dynamics, as well as the porosity distribution of collected bulk solids, can be extracted from the simulation, supporting engineers to enhance the design and operation of equipment.

The design of machinery for handling granular materials relies mainly on empirical methods and in-house engineering knowledge. This traditional approach provides incremental improvements that are often limited. Advancements in simulation and optimization can offer a promising alternative approach. Most of the research involved in improving or optimizing equipment design does not include the realistic performance of the new prototype and as such it is uncertain that the predicted performance is also guaranteed in practice. In this study, a design framework for a new generation of machinery handling granular materials, grabs, has been established that includes a full-scale validation step. This has been proven to lead to a breakthrough in equipment design. This design framework uses a co-simulation between Discrete Element Method (DEM) and Multi Body Dynamics (MBD), thus, capturing operational conditions in full-scale. The DEM simulation supported design step integrated as the main step to generate new prototypes. The performance of the prototype is evaluated by conducting full-scale experiments, thus validating the adequacy of the new design as well as the accuracy of the co-simulation. Through this a full design cycle has been fulfilled and a validated model has been achieved that is independent of specific design configurations.