This question concerns the expansion of non-commutative algebra $[X,Y] \neq 0$ for two operators $X,Y$. One can think of $X$ and $Y$ as some matrices.
If $[X,Y] = 0$, we have
$$e^{t(X+Y)}= e^{tX}~ e^{tY}$$
If $[X,Y] \neq 0$, We know the Zassenhaus formula or the Baker–Campbell–Hausdorff formula: $$e^{t(X+Y)}= e^{tX}~ e^{tY} ~e^{-\frac{t^2}{2} [X,Y]} ~ e^{\frac{t^3}{6}(2[Y,[X,Y]]+ [X,[X,Y]] )} ~ e^{\frac{-t^4}{24}([[[X,Y],X],X] + 3[[[X,Y],X],Y] + 3[[[X,Y],Y],Y]) } \cdots$$
This expresses $e^{t(X+Y)}$ in terms of $e^{tX}$ and $e^{tY}$, and their further commutators $[X,Y]$.
Question: Do we have a similar form for $\cos(A+B)$ when $[A,B]=C \neq 0$? (We may take $[C,A]=[C,B]=0$ for the simplest case to extract the first order term.)
If $[A,B]=0$, we have $$\cos(A+B)=\cos(A)\cos(B) -\sin(A)\sin(B).$$
If $[A,B]=C \neq 0$, do we have some similar expression like the Zassenhaus formula or the Baker–Campbell–Hausdorff formula: $$\cos(A+B)=\cos(A)\cos(B) \dots-\sin(A)\sin(B) \dots+ \dots$$
Can we express $\cos(A+B)$ in terms of $\cos(A)$,$\cos(B)$,$\sin(A)$,$\sin(B)$ and some function of $C$?
It seems to me that if $[A,B]=C$ with $[C,A]=[C,B]=0$, it will be a simple case.
We have $$e^{A+B}=e^A e^B e^{-\frac{1}{2}[A,B]}$$
and $$\cos(A+B)=\frac{e^{i(A+B)}+e^{-i(A+B)}}{2}=\frac{e^{iA}e^{iB}e^{\frac{1}{2}[A,B]}+e^{-iA}e^{-iB}e^{\frac{1}{2}[A,B]}}{2}$$ $$=e^{\frac{1}{2}[A,B]}\frac{e^{iA}e^{iB}+e^{-iA}e^{-iB}}{2}=e^{\frac{1}{2}[A,B]}\big(\cos(A)\cos(B) -\sin(A)\sin(B)\big).$$
Notice that $\frac{e^{iA}e^{iB}+e^{-iA}e^{-iB}}{2}=\cos(A)\cos(B) -\sin(A)\sin(B)$ is true. and notice that we use the condition $[A,B]=C$ with $[C,A]=[C,B]=0$.
Maybe someone else can fill in the higher order term computation?