Mill-knurling as an alternative to laser welding for automotive drivetrain assembly

A novel technique for drivetrain assembly -“mill-knurling and press-fitting (MKPF)” is proposed as an alternative to laser welding or bolting. This joining technique involves the press fitting of two mating surfaces, one with mill-knurled teeth and the other which is of a relatively softer material, enabling it to flow over the teeth making a joint. This process is applied within the rear axle differential subjected to fluctuating torque loads. Experimental analysis and simulation is used to compare the functional feasibility and the potential benefits of mill knurled joints with laser welded and bolted joints currently used in differential/bevel gear assembly.