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Currently, the demand for surface treatment methods like plasma electrolytic polishing (PeP)—a special case of electrochemical machining—is increasing. This paper provides a literature review on the fundamental mechanisms of the plasma electrolytic polishing process and discusses simulated and experimental results. The simulation shows and describes a modelling approach of the polishing effect during the PeP process. Based on the simulation results, it can be assumed that PeP can be simulated as an electrochemical machining process and that the simulation can be used for roughness and processing time predictions. The simulation results exhibit correlations with the experimentally-achieved approximation for roughness decrease. The experimental part demonstrates the results of the PeP processing for different times. The results for different types of roughness show that roughness decreases exponentially. Additionally, a current efficiency calculation was made. Based on the experimental results, it can be assumed that PeP is a special electrochemical machining process with low passivation.

Electrochemical Machining (ECM) with closed electrolytic free jet (Jet-ECM) is an innovative procedure in micro manufacturing technology which is based on anodic dissolution of metallic work pieces. Main advantage of Jet-ECM in comparison to other ECM processes is the restriction of the electric current to a limited area by the jet. Micro structured surfaces and complex three-dimensional micro geometries can be machined by help of different nozzle movements. In this study the Jet Electrochemical Machining is used to generate micro cavities in different steels to investigate the influence of the material properties on the removal process. Current efficiency, machined geometry and surface properties of the processed areas were analyzed and compared.

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