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In this paper, some features confronted in finite element analysis of combined clinching and pull-force testing process for process optimal design are investigated to suggest an engineering approach to solve the problems occurring in conducting finite element analysis and clinching process optimal design. An optimized finite element analysis model with appropriate blank size and number of finite elements, based on elasto-plasticity, is proposed in terms of reliable prediction of pull-force. The optimized finite element mesh system in terms of good mesh regularity at the material-die interface is emphasized to obtain steady predictions of pull-force for clinching process design optimization. Rigid-plastic finite element method is criticized from the standpoint of pull-force prediction while implicit elasto-plastic finite element analysis is strongly recommended especially for clinching process design optimization. An optimal process design is conducted using the proposed schemes. The engineering insights obtained from this paper can help gain a better understanding of the deformation history and can pave the way for a more realistic optimal process design. [ABSTRACT FROM AUTHOR]