Firstly, I am including only the main actors not character artists. Secondly guest appearances are not included.
Akshay Kumar has overall worked the most with Sunil Shetty. The pair has worked in 14 films together not including guest appearances otherwise the list will reach around 18 films. The prominent films they worked together includes- Waqt Hamara Hai (Average), Mohra (Blockbuster), Hum hai Bemisal (Disaster), Sapoot (Flop), Hera Pheri (cult classic), Dhadakan (Average), Jaani Dushman (Flop), Aawara Pagal Deewana (Moderate success), Aan Men at Work (Flop), Deewane Hue Pagal (Flop), Phir Hera Pheri (Superhit), De Dana Dan (Average), Thank You (Flop), Welcome to the Jungle (verdict disputed)
Amitabh Bachchan has worked the most with Hema Malini. Excluding guest appearances the two have worked in around 16–17 films together though they were not paired together in many of these films like Sholay, Gehri Chaal, Do aur Do Paanch etc. The important films include- Gehri Chaal (Flop), Kasauti (above average), Sholay (All Time Blockbuster), Trishul (Superhit), Do aur Do Paanch (Flop), Naseeb (Hit), Satte pe Satta (Semi Hit), Desh Premi (Average), Andha Kanoon (Superhit), Nastik (above average), Baghban (Hit), Veer Zaara (Superhit), Babul (Flop), Bbudah hoga Tera Baap (Flop), Ganga (Bhojpuri film), Gangotri (Bhojpuri film), Arakshan (Flop)
Shahrukh Khan has done the most number of films with Juhi Chawla. The two have worked in 8 films together without guest appearances. He had done 8 films with Kajol as well but then there is a 9th film Bhootnath where SRK did more than a guest appearance so for a tie breaker I will count that as a 9th film. Their films together includes- Raju Ban Gaya Gentleman (Semi Hit), Darr (Blockbuster), Ram Jaane (Hit), Yes Boss (Hit), Duplicate (Flop), Phir Bhi Dil hai Hindustani (Flop), One 2 ka 4 (Disaster), Paheli (Flop, not paired together) and Bhootnath (Average).
Salman Khan has done the most number of films with his brother Sohail Khan as an actor as well as director not including cameos. As actors they have worked in 7 films together - Maine Pyar Kyon kiya (Hit), Heroes (Flop), God Tussi Great Ho (Flop), Salaam E Ishq (Disaster), Main aur Mrs Khanna (Disaster), Veer (Below Average), Tube light (Below Average). They have also worked together as actor director in films like Auzaar (Flop), Pyar Kiya to Darna Kya (Superhit), Hello Brother (Flop), Partner (Blockbuster), Jai Ho (Semi Hit) and produced films like Lucky No time for Love (Average) and Ready (Blockbuster). Purely as actor surprisingly Salman has worked in 9 films with Karishma Kapoor not including cameos- Nischay (Flop), Jagruti (Flop), Andaz Apna Apna (cult classic, not paired), Jeet (superhit), Judwa (Hit), Ham Saath Saath hai (Blockbuster), Biwi no 1 (Superhit), Dulhan ham Le jayenge (Hit), Chal Mere bhai (flop).
Aamir Khan worked the most with Juhi Chawla with whom he worked in 7 films. These films included- Qayamat se Qayamat Tak (Blockbuster), Love Love Love (Flop), Tum Mere Ho (Average), Daulat ki Jung (Flop), Ham hai Rahi Pyar ke (Hit), Aatank hi Aatank (Disaster), Ishq (Superhit)