Abstract: A shaft coupling assembly includes a male shaft having a splined portion including a plurality of male shaft teeth formed on an outer surface of the male shaft, a lead-in zone formed on at least one tooth of the plurality of male shaft teeth, the lead-in zone including a pair of flank surfaces, a female shaft having a splined portion including a plurality of female shaft teeth formed on an inner surface of the female shaft, and a first flank surface and a second flank surface formed on adjacent female shaft teeth of the plurality of female teeth. The first flank surface and the second flank surface are stepped from each other such that a first distance between first flank surfaces of the adjacent female shaft teeth is greater than a second distance between second flank surfaces of the adjacent female shaft teeth.

Abstract: In accordance with an exemplary embodiment of the invention, a shaft coupling is provided. The shaft coupling comprises a first shaft having a splined outer surface, a tubular second shaft having an end surface and a splined inner surface, the second shaft receiving the first shaft along a longitudinal axis of the second shaft, and at least one stake extending axially into the second shaft end surface. The at least one stake deforms at least a portion of the splined inner surface to facilitate an interference fit between the first and second shafts and configured to resist a predetermined axial separation load being applied to the first and second shafts.

Abstract: In accordance with an exemplary embodiment of the invention, a shaft coupling is provided. The shaft coupling comprises a first shaft having a splined outer surface, a tubular second shaft having an end surface and a splined inner surface, the second shaft receiving the first shaft along a longitudinal axis of the second shaft, and at least one stake extending axially into the second shaft end surface. The at least one stake deforms at least a portion of the splined inner surface to facilitate an interference fit between the first and second shafts and configured to resist a predetermined axial separation load being applied to the first and second shafts.