To address the technical bottleneck of traditional knurling processes failing to meet precision requirements for expected interference fit dimensions， an innovative arc-topped knurling structure was proposed. To systematically evaluate the mechanical characteristics and mating performance of the proposed structure， a comprehensive investigation combining theoretical modeling， finite element simulation， and experimental validation was conducted. Initially， the accuracy of the finite element model was verified through theoretical modeling of cylindrical interference fits. Subsequently， finite element models for both conventional knurling and arc-topped knurling were established to investigate the influence patterns of key geometric parameters （tooth height and pitch） on stress distribution characteristics. Building upon this foundation， comparative analysis of mechanical performance differences among cylindrical interference fits， conventional knurling interference fits， and arc-topped knurling interference fits was performed， with particular emphasis on analyzing variations in push-out to press-in ratios， accompanied by systematic experimental validation. The research demonstrates that the arc-topped knurling structure exhibits superior mechanical performance， achieving a push-out to press-in ratio of 1.979. This represents a 52.231% improvement over cylindrical interference fits （1.3） and a 16.412% enhancement compared with conventional knurling structures （1.7）， essentially approaching the performance level of axial-radial coupled knurled shafts （2.0）.