A spline coupler connects two spline shafts together, with two basic styles: same spline to same spline and different spline to different spline. The coupler uses multiple splines to place torque and power at up to 40 points within the coupler, making it stronger than a universal joint. The grooves within a splined coupler are first cut and then hardened by heat treating the entire coupler. Composite materials, such as carbon fiber, are also used in the production of splined joints for high-performance vehicles.
A spline coupler is a device used to secure two spline shafts together. The typical splined joint represents the female connection and looks like a short piece of pipe with grooves or grooves cut into it; a common spline shaft represents the male connection and has splines or grooves machined into the outside of the shaft. There are two basic styles of spline coupler: same spline to same spline coupler, and different spline to different spline coupler. Many couplers are designed to allow connection of a different type of component to another type of component. This is usually to complete a modification intended to help a running or performance issue with a vehicle.
For some of the more challenging components, such as an all-wheel drive transmission or drop box, the splined coupler is the only method that can be successfully used over and over again to join two independent components and form a driveline. Unlike a universal joint which places torque and power at two points, the splined coupler uses multiple splines to place torque and power at up to 40 points within the coupler. With a spline, the strength lies in the number of splines that are used in the coupler. Similar to a drive axle, the more splines, the stronger the axle and the less chance there is of the axle slipping inside the differential.
To impart strength to the coupler, it is common for the grooves within a splined coupler to be first cut and then hardened by heat treating the entire coupler. Some joints are machined from cut-to-length pieces of pipe, however, more exotic metal joints are typically machined from a block of billet steel or aluminum. Billet steel and aluminum are renowned for their superior strength and uniform grain created by the forging process. This type of material is often used in extremely tight tolerance, high performance applications due to its ability to be machined to project plans.
Technology has enabled the use of composite materials, such as carbon fiber, in the production of splined joints. This typically involves the use of a machined mold where the carbon fiber material is applied and machined into grooves machined into the surface of the mold. This intricate work commonly equates to higher prices and longer production times. The composite coupler is typically found in aviation, spacecraft, satellites, and high-performance vehicles. Drag racing vehicles and Indy® type cars are often equipped with lightweight and strong composite couplers in a variety of applications.
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