Deep-hole drilling technology is commonly used in the aerospace and automobile industries, for new-energy equipment manufacturing, and in the high-tech industries. While this technology produces high-quality holes, higher quality is pursued. A method to improve the processing quality is to suppress the vibration modes associated with long shafts. This problem was addressed with an aim of real-time application. In addition, a higher goal was set by way of providing a solution (in full) to the associated problem, to shed light on processes that bear similar features in manufacturing and for other industries. An operable control scheme was constructed by transforming the system dynamics to modal space for modal decoupling and truncation. The modal displacement and velocity information estimated by the modal filtering were introduced into the feedback gain matrix. All obstacles in traditional physical space were shunned. A damper/sensor position optimisation algorithm was suggested to minimise the modal spillover and acquire modal orthogonality, which led to a new method that has an edge on all preceding methods because of its stronger ability. A system capable of real-time suppression of modal vibration in a deep-hole drilling tool was built and implemented. Using hole roundness error as the criterium, it was found that further improvement of hole quality was achieved. The idea presented in this work may pave the way for elevating the quality of other manufacturing processes with similar weak stiffness features, such as those seen in long-shaft tools or thin-wall workpieces. The method may also provide a reference for other industries with relevant or comparable problems.

深孔钻探技术通常用于航空航天和汽车工业，新能源设备制造以及高科技工业。尽管此技术可产生高质量的孔，但仍追求更高的质量。一种提高加工质量的方法是抑制与长轴相关的振动模式。为了实时应用，解决了该问题。此外，通过提供（完整）相关问题的解决方案来设定更高的目标，以阐明在制造业和其他行业具有相似特征的工艺。通过将系统动力学转换为模态空间以进行模态解耦和截断，构建了可操作的控制方案。通过模态滤波估计的模态位移和速度信息被引入到反馈增益矩阵中。避免了传统物理空间中的所有障碍。提出了一种阻尼器/传感器位置优化算法，以最小化模态溢出并获得模态正交性，这导致了一种新方法，该方法由于其更强大的功能而在所有前述方法中都占优势。建立并实现了能够实时抑制深孔钻具中的模态振动的系统。使用孔的圆度误差作为标准，发现实现了孔质量的进一步改善。这项工作中提出的想法可能会为提高具有类似弱刚度特征的其他制造过程的质量铺平道路，例如长轴工具或薄壁工件中看到的那些。