Clinching is a joining technology, which does not need any auxiliary joining elements, and which enables a wide variety of different materials to be joined. Therefore, it fulfills the demands of multi‐material lightweight design. Because of the translational tool movement, continuous joining is not possible. To overcome this disadvantage, roller clinching uses rotational tool movement. It is a novel joining technology, which combines the advantages of conventional clinching with rotary processes. Based on previous studies, the process scalability of roller clinching is investigated within this study. A comprehensive experimental parameter study is thus shown to reveal the influence of the following geometrical process parameters: roll distance, punch and die rolling radii and clinchpoint diameter. Furthermore, process limits are identified. The joint quality is evaluated using three different methods. Microsections are recorded and the joint strength is measured using pull‐out as well as shear tests. The results are shown in relation to each other and connected to the particular failure mode. Finally, conclusions are derived to enable the further development of the process of roller clinching.     «

Clinching is a joining technology, which does not need any auxiliary joining elements, and which enables a wide variety of different materials to be joined. Therefore, it fulfills the demands of multi‐material lightweight design. Because of the translational tool movement, continuous joining is not possible. To overcome this disadvantage, roller clinching uses rotational tool movement. It is a novel joining technology, which combines the advantages of conventional clinching with rotary processes...     »