Polyoxymethylene (POM), as an energy-saving material, is widely applied in the manufacturing field. Yet, research on the rectangular clinching process between metal and POM sheets is still lacking. In this paper, the rectangular clinching process for POM and Al5052-H32 plates was investigated. The feasibility of the metal-polymer hybrid component had been analyzed in terms of diverse forming forces and diverse joint layout angles, respectively. The mechanical characteristics were appraised by the lap-shear test. The failure modes of rectangular clinched joints produced under diverse forming conditions had also been analyzed. The results showed that the optimal forming force of rectangular clinched joints was 14 kN, in which the lap-shear strength was 1090 N. Furthermore, the rectangular clinched joints produced under the joint layout angle of 90 degrees could withstand the maximum lap-shear load (1415 N) under the optimal forming force. The failure mode was the separation of two plates and the fracture of the bridge structures.
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