<![CDATA[Submersible pumps are commonly used to handle heterogeneous fluids, including water, mud, gravel, and other sediments, particularly in traditional coal mining operations. A submersible pump used by a conventional coal mining company in Bayah City exhibited severe corrosion after approximately one week of service. Corrosion-induced perforations in the pump cover obstruct suction, thereby reducing mining productivity and necessitating weekly replacement. This reverse engineering (RE) study aims to generate accurate product geometry data for further development and to enhance the corrosion resistance of the pump casing beyond one week of operation, thereby improving mining productivity through reduced maintenance downtime. The RE workflow integrates 3D scanning, CAD remodeling, finite element analysis, additive manufacturing (AM), and field testing. The process successfully produced a high-fidelity 3D geometric model of the pump cover suitable for product development and yielded a redesigned pump cover manufacturable via injection molding with a maximum deformation of 0.75 mm and a maximum von Mises stress of 17.6 MPa. Simulation results indicate an outlet water flow rate of 0.2 m³/min, while field testing demonstrates that the improved pump cover can operate for more than six months. This study contributes to the advancement of reverse engineering applications in mining equipment by demonstrating an integrated digital engineering framework that combines 3D scanning, computer-aided design, numerical simulation, additive manufacturing, and field validation to accelerate product redesign and significantly improve the service life of corrosion-prone components. Next research recommendations should focus on material optimization and surface treatment to enhance durability. Innovation opportunities lie in advanced casting routes combined with microstructure control and protective surface coatings to improve performance and service life.]]>
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