<p>The combined simple shear extrusion-forward extrusion (CSSE-FE) process was recently introduced as a new technique of severe plastic deformation (SPD) for deforming bulk materials. With the unique design of the die channel, this technique can impose large strains on engineering materials without repeating the process cycle. In this study, the effect of die geometric parameters, friction coefficient, and work-piece dimensions were numerically investigated on the distribution of equivalent plastic strain, filling fraction of the die outlet channel, and pressing load in the CSSE-FE process using ABAQUS 6.14 software for 1050 aluminum alloy. Pressing load and microhardness measurements were used to validate the simulation results. There is a good agreement between the experimental and simulation results. By increasing the friction coefficient from 0 to 0.06, the maximum amount of equivalent plastic strain was decreased by about 25.78%, and the deformation uniformity was increased by about 38.75%. In this study, gaps were not formed between the sample and the die outlet channel. It indicates that the CSSE-FE process can provide an ideal mode for sample deformation. Also, by increasing the die maximum distortion angle from 30° to 60°, the sample was deformed with the highest deformation uniformity at the lowest pressing load.</p> Graphical Abstract <p></p>