The mechanical clinching process was a new alternative method for metal sheet joining technology which geometrically constrains two sheets by local deformation. The tools geometry was crucial since it directly influences the joint resistance. How to determine the value of the tools parameters was always the difficulty. In view of this, a fast and efficient tools design method was proposed in this paper based on the mechanical relationship of process variable and FE-analysis technology. Besides, the tensile test and shear test results were shown in this study for proving the validity of the method which indicated that this design method could meet the requirements of the joint resistance and would bring much more convenience in clinching tools design.