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In order to manufacture a uniform ultrafine-grain age-hardening aluminum alloy without damage, and to overcome the severe plastic deformation of traditional extrusion process with equal diameter angle, which brought to time-consuming problems such as multiple loading and charging, mechanical processing of bar, a new parallel extrusion process of rotated channel and equal diameter angle was proposed. Then, multiple shear deformation areas were set up in the channel, and the shear deformation direction and angle of samples were changed by setting rotating channel between extrusion channels with two equal diameter angles. Therefore, the Bc process path was conducted, and the deformation uniformity was improved. According to the orthogonal experiment method, the interior angle Φ, the outer corner Ψ, the lead angle γ, the oval factor m and the length of L1 were chosen as facts, and extrusion simulations were realized by the finite element method under 16 simulation experiments of different die parameters. Furthermore, the equivalent strain,equivalent stress, damage and deformation uniformity coefficient were analyzed as the indexes of orthogonal experiment method, and the influences of them on extrusion process were conducted. The simulation results show that the reasonable values are angle Φ of 90°-120°,the outside corners Ψ of 30°-40°, the lead angle γ of 60°-80° and m of 1.2-1.4,L1 and L3 of d-1.5d in good extrusion channel respectively.
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