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In order to study the relationships between shatter resistance index and physical characteristics of tobacco leaves, correlation analysis, factor analysis, and gray correlation analysis were carried out on the tobacco leaves shatter resistance index and physical characteristics index, and the tobacco leaves of different regions were grouped according to the analysis results. The result showed as follows: shatter resistance index of tobacco leaves was significantly positively correlated with tensile strength, elongation, recovery, and thickness, and significantly negatively correlated with brittleness, shear force, cohesion, elasticity, adhesion, and penetration. Fac-1 (determined by tensile strength, cohesion, elasticity, recovery, adhesion, penetration), Fac-2 (determined by shear force, thickness), Fac-3(determined by elongation, brittleness and hardness) and Fac-4 (determined by adhesion) common factors were extracted from 12 physical characteristics, and the cumulative contribution rate was 88. 201%, the contribution rate of Fac-1 is significantly higher than the other three common factors, indicating that Fac-1 had the most significant impact. According to the contribution rate of the common factors and the factor score coefficient matrix, the comprehensive factor score model of the physical characteristics of tobacco leaf was established as F = 0.46FFac-1 +0.23FFac-2 +0.20FFac-3 +0.11FFac-4. Fac-3 had the greatest impact on the shatter resistance index of tobacco leaves, and Fac-4 had the least impact. According to cluster analysis, the tobacco leaves were divided into 4 categories, so that the comprehensive physical characteristics of the same category of tobacco leaves were closer, and the process parameters could be adjusted and processed into groups to reduce the breaking of tobacco leaves during processing. [ABSTRACT FROM AUTHOR]