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Residual stresses and deformation of static bonding multi-layer Pyrex7740 glass and aluminum have important effects on performances of bonding parts. The stress and strain finite element analysis of anodic bonding can optimize the structure and process design, reduce the workload of the experiments, shorten the production cycle, improve the bonding quality, and reduce the process costs. In this paper, residual stresses and deformation in the static bonding two-layer(glass/aluminum), three-layer(glass/aluminum/glass),five-layer(glass/aluminum/glass/aluminum/glass)and seven-layer(glass/aluminum/glass/aluminum/glass/aluminum/glass) samples have been analyzed using nonlinear finite element simulation software MARC. The simulation results show that the shear stress distribution and deformation distribution in different multi-layer glass and aluminum samples are similar. The stress distribution along thickness at different typical positions in all multi-layer samples has characteristics of pulse pattern, which has pulse peak at the position of transition layers and then decreases abruptly to the minimum value at the positions of glass and aluminum. The maximum shear stress is located in the outside surface area in the transition layer between the top unconstrained glass layer and aluminum layer. The displacement distribution along thickness in all multi-layer samples increases gradually from the constrained bottom glass layer to the top unconstrained glass layer with abrupt step increase in the aluminum layers. The maximum deformations occur in aluminum layers. It is found that the minimum deformation distortion and the minimum shear stress occur in the three-layer static bonding sample.
Residual stresses and deformation of static bonding multi-layer Pyrex 7740 glass and aluminum have important effects on performances of bonding parts. The stress and strain finite element analysis of anodic bonding can optimize the structure and process design, reduce the workload of the experiments, shorten the production cycle, improve the bonding quality, and reduce the process costs. In this paper, residual stresses and deformation in the static bonding two-layer (glass / aluminum), three-layer glass / aluminum / glass / aluminum / glass) and seven-layer (glass / aluminum / glass / aluminum / glass / aluminum / glass) samples have been analyzed using nonlinear finite element simulation software MARC. The simulation results show that the shear stress distribution and deformation distribution in different multi-layer glass and aluminum samples are similar. The stress distribution along thickness at different typical positions in all multi-layer samples has characteristics of p ulse pattern, which has pulse peak at the position of transition layers and then decreases abruptly to the minimum value at the positions of glass and aluminum. The maximum shear stress is located in the outside surface area in the transition layer between the top unconstrained glass layer The displacement distribution along thickness in all multi-layer samples increment gradually from the constrained bottom glass layer to the unconstrained glass layer with abrupt step increase in the aluminum layers. It is found that the minimum deformation distortion and the minimum shear stress occur in the three-layer static bonding sample.