In order to mend cutting instability of ball-end milling cutter caused by the changes of cutting loads in high speed milling hardened steel, we perform the modal analysis and heat-force coupling field analysis of cutter, carry out the experiment of high speed milling hardened steel, investigate the character and effect factor of physical field distribution in high speed ball-end milling hardened steel, and propose the method about the match of diameter and overhang for depressing cutter vibration. Results indicate that the decrease in the ratio of overhang to diameter can transform the first modal shape of cutter from bending modal shape into torsion modal shape. The diameter of cutter is from 30mm to 20mm, the overhang of cutter is from 125mm to 90mm, heat-force coupling field distribution changes slightly, resonance of cutter does not occur, and efficiency in machining hardened steel can be improved effectively by higher cutting speed.
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