A novel severe plastic deformation process named half channel angular extrusion (HCAE) is proposed in order to produce bulk UFG materials. In HCAE process, equal channel angular extrusion (ECAE) and conventional forward extrusion process is integrated to increase the strain per pass and effectiveness of the SPD process. Three-dimensional finite element analysis was carried out to study the deformation behavior of the materials in the HCAE process. HCAE process was performed experimentally on commercially pure aluminum (AA1050) and micro-Vickers hardness test was used to measure the distribution of hardness on the section of normal to the extrusion direction. The results show that HCAE is able to impose more intensive strains per pass and give rise to higher micro-hardness than ECAE.