A validated co-simulation of grab and moist iron ore cargo: Replicating the cohesive and stress-history dependent behaviour of bulk solids

Abstract 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.