Success Story: Custom WH12 Wear Parts for 7495HR HD Machine – Exceeding OEM Durability

At Beneparts Mining we take pride in delivering high-performance, customized wear parts that meet and exceed our clients' expectations. One of our most notable successes involves the development of wear parts for a 1000-ton 7495HR machine, where we not only matched the durability of OEM parts but also improved performance based on real-world usage feedback.

The Challenge

Our client, a leading mining operator, approached us with a challenge: to develop custom wear parts for their 7495HR machine that could match or exceed the lifespan of the original equipment manufacturer (OEM) parts. The machine operates under extreme conditions, requiring wear parts that can withstand high abrasion and impact while maintaining optimal performance.

Our Solution

Initial Consultation and 3D Design Review

The process began with the client providing us with detailed 3D models of the existing wear parts. Our engineering team conducted an in-depth analysis of the design, material composition, and operational conditions. Through collaborative discussions with the client, we identified key areas for improvement and customization.

Material Selection and Prototyping

Leveraging our expertise in wear-resistant materials, we selected advanced alloys specifically engineered for high abrasion and impact resistance. Using state-of-the-art prototyping technology, we developed a custom design that optimized the geometry and material distribution for enhanced durability.

Rigorous Testing and Validation

After manufacturing the initial batch of wear parts, we conducted extensive in-house testing to ensure they met our stringent quality standards. The parts were then sent to the client for field testing. After several months of operation, the client confirmed that our custom wear parts achieved the same lifespan as the OEM parts, validating our design and material choices.

Key Wear Parts Delivered (Partial List) WH-12:

Continuous Improvement: Second Order and Beyond

Following the success of the initial order, the client placed a second order for additional wear parts. This time, we took the opportunity to further refine the design based on real-world usage data and feedback from the client. Key improvements included:

Enhanced Geometry: We adjusted the shape and thickness of critical areas to better distribute wear and extend the parts' lifespan.

Material Optimization: Based on the client's operational conditions, we fine-tuned the material composition to further improve resistance to specific types of abrasion and impact.

Streamlined Installation: We incorporated design changes to make the parts easier to install and maintain, reducing downtime for the client.

The Results

The updated wear parts delivered even better performance, exceeding the client's expectations. The client reported:

Extended Lifespan: The improved parts lasted longer than both the original OEM parts and our first-generation custom parts.

Reduced Downtime: The optimized design and easier installation process minimized machine downtime, improving overall operational efficiency.

Cost Savings: By extending the lifespan of the wear parts and reducing maintenance requirements, the client achieved significant cost savings.