A five-zone describing model for extrusion of aluminum/copper clad composite was established. Stress and strain were also analyzed by finite element method. The distribution rules of grain size were researched by critical shear strain theory, and zoning phenomenon of grain size was discovered. The grain size of deformed aluminum material becomes gradually finer from center to the interface. The grain size is much fine and the critical shear strain reaches the maximum value in the interface. The grain size of copper material reduces gradually from center to both the interface and exterior surface, which is caused by the higher value of critical shear strain in the interface and exterior surface. The analysis results were verified by microstructure observation and mechanical properties test, indicating that the distribution of grain size for cold extrusion forming can be interpreted by critical shear strain theory.