Many analyses relating to shearing of sheet products have already been reported. Elasto-plastic analyses to evaluate residual stress inside the sheet have also been increasing. However, only a few papers have shown measured residual stress distributions, so very few in-depth comparisons between calculated stress levels and experimental results are available. In this study, considering ductile fracture conditions of thin steel sheets, two simulations of the shearing process have been carried out. The results of the simulations agree well with experimental ones, such as cut surface shape and residual stress distribution in the vicinity of the cut surface measured using synchrotron radiation. As another example, after punching a round hole to about half the sheet thickness, i.e., extruding a cylindrical protrusion, a round interlock is formed by subsequently laying of a sheet on the others. A simple four-layer interlock simulation model predicts accurate residual stress distributions compared with X-ray diffraction data. The above-mentioned simulations would be promising tools benefitting the performance of steel products by reducing residual stress levels.
