Cold expansion of fastener/rivet holes is a common way to generate beneficial compressive residual stress around the fastener hole. In this study, cold expansion process was simulated by finite-element method in order to determine the residual stress field around two cold expanded holes by varying the plate thickness and expansion ratio of the hole. The model was developed in ANSYS and assigned to aluminium alloy 7475-T61 material model. The results showed that the residual stress become more compressive as the plate thickness is increased up to t/d = 2.6 and decreased for further level of thickness. In addition, the residual stress at the edge of the hole become more compressive as the expansion ratio is increased up to 4.5 and decreased for further level of expansion. This study also found that the residual stresses near the entrance and the exit face of the plate are less compressive than the residual stresses on the mid-thickness of the plate. © 2017 Published under licence by IOP Publishing Ltd.