In the present study a new design of the equal channel angular pressing die and punch is introduced. The new design eliminates the deflection of the punch and at the same time lowers the frictional forces by reducing the contact area. In order to show the capability of the new design, the Al‐7075 alloy samples were processed in two equal channel angular pressing dies. The measured data for the novel and conventional equal channel angular pressing processes were compared. The microstructure of the processed samples was examined with scanning electron microscopy and transmission electron microscopy. The results of the experimental study revealed that the novel die can fully eliminate the risk of the punch deflection and simultaneously reduce the maximum required pressing force by about 3.1 % to 9.8 % for 16 % to 40 % reduction in frictional contact surfaces. The analysis of experimental results showed that there is non‐linear relation between the frictional contact area and the pressing load. In addition, it is shown that despites high contact pressures and high temperatures the use of graphite as a lubricant between sliding surfaces can considerably reduce the pressing load.

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