The through-feed method in centerless grinding allows manufacturers to produce cylindrical parts at much higher levels of productivity than can be achieved with in-feed grinding, so it has been extensively employed in industry. However, its rounding mechanism is not yet well understood due to the complexity of the through-feed process. This paper presents the fundamental parameters, such as material removal rates, forces, and so on in the through-feed grinding, and analyses on the grinding system with feedback loops, including regenerative functions and the machine dynamic functions. Further, the characteristic roots of the system, representing the number of waves and the growth rates of the harmonics in roundness, are identified at each grinding position from entry to exit. To evaluate the grinding process stability, a rounding stability index (RSI) was proposed. It was demonstrated that the analytical tool modeled in this paper can identify the optimum operational conditions by the RSI for achieving desired grinding productivity and accuracy. Finally, the model is verified with grinding tests, and the nm-order roundness obtained by the tests is shown.
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