Multi-objective optimization of grinding process parameters for improving gear machining precision

• A multi-objective optimization model links grinding process parameters—cutting speed, feed rate, and cutting depth—to gear tooth surface, profile, and lead deviations. • Response surface methodology (RSM) enables efficient experimental design, yielding optimal process parameters for worm wheel gear grinding. • GRA-PCA, PSO, and GA-PSO all improve gear machining precision, but GA-PSO achieves superior results. • The findings provide a systematic route to meet ISO 1328-1:2013 grade 4–5 precision requirements for new energy vehicle gears.