In the present work, cutting-force models of single-tooth and multi-teeth face-milling cutters were set up. Based on a spectrum analysis of cutting force, the vibration mechanism of a face-milling cutter of irregular pitch was investigated theoretically. The single-objective function and constraint conditions were derived. A general-purpose irregular-pitch face-milling cutter subsequently was designed and tested, and its performance was compared with that of a regular-pitch cutter. The experimental results showed that the irregular-pitch face-milling cutter not only reduces vibration and noise but also enhances surface-finish quality.