The effectiveness of a machining process can be determined by analysing the quality of the generated surface and the rate of tool wear. Stellite is highly challenging to machine, which is why it is primarily processed through grinding methods. This study concentrates on the impact of cutting parameters and tool wear (VBb, KBb) on the created surface roughness surface (Rt, Ra, Rz) during the orthogonal cutting of Stellite 6, which is overlaid on a steel surface, C45, prepared by means of HP/HVOF (JP-5000). The results indicate that the dominant influence on the change in the total roughness profile height value (Rt) is the mutual interaction of cutting speed and depth of cut at 16% (p < 0.000). The greatest impact on the change in the mean arithmetic deviation of the roughness profile (Ra) value is the interaction of cutting speed, tool front angle, and depth of cut with a 15% share (p < 0.000), as well as on the change in the Rz value (15%) and tool wear VBb (25%). This investigation lays the groundwork for potentially substituting the processing of flat surfaces with hardened layers created by thermal spraying (such as Stellite 6) with grinding or methods that offer greater efficiency from both economic and technological perspectives.

College of Engineering and Technology American University of the Middle East Egaila 54200 Kuwait

Department of Machining Technology Faculty of Mechanical Engineering University of West Bohemia 301 00 Pilsen Czech Republic

Department of Mechanical Engineering Faculty of Technology Institute of Technology and Business in České Budějovice 370 01 České Budějovice Czech Republic

Institute of Design and Engineering Technologies Faculty of Engineering Slovak University of Agriculture in Nitra 949 76 Nitra Slovakia

Institute of Electrical Engineering Automation Informatics and Physics Faculty of Engineering Slovak University of Agriculture in Nitra 949 76 Nitra Slovakia

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