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I have a cheap CAP barbell that came with some cheap plates. The bar has pronounced ridges on the sleeves (compared to the SS bar which has very fine low ridges) to the point where loading and unloading the bar makes a loud ZIP sound. I think that in this case the ridges do help plates stay on the bar, not because of the change in surface area or friction, but because there is significant slop in the ID of the plates, and they don't slide off the sleeves so much as wobble and "walk" down the sleeve during the course of a lift. The ridges grab the edges of the ID of the plates, and keep them in place a little bit. So there is more to the ridged/smooth issue than just friction and surface area, at least in some cases.
I am not a tribologist, but I can confirm that the chromed+ridged sleeves on my Ohio Power Bar are both slippery and pretty.
Rust works pretty well.
Plates that slide off are not necessarily "moving back and forth orthogonal to the cross-section of the bar". A plate with a very large inner diameter that will easily slide off, can do so without moving orthogonal to the cross-section. The same little area stays in contract with the bar whole sliding. I'm sure you can picture this in your head. However, now introduce some imperfections in the machining of the bar. This does cause the plate to move back and forth orthogonal to the cross-section as it moves along the axis of the bar. For the plate with the very large inner diameter, it doesn't matter. The plate moves up and down a bit as it slides, but the side opposite the point of contact never hits the bar. Now take a snug fitting plate with a smaller inner diameter. What happens as the plate moves up and down? It comes in contact with the bar even if it just moves a little, due to the snug fit. So now it is bouncing back and forth. And each bounce is another normal force between the plate and bar that adds to the force of friction opposing the bar.
So the area still doesn't matter. It's that the plate and bar are constantly colliding, adding to the normal force which resists sliding.
I think that might only be half of it though. Placing a plate onto a bar that that fit very snug, may deform the plate and the bar, which would apply a pressure to the other surface at all points of contact, and that pressure would add to the normal force as well.
that's my guess.
Yes. "Not necessarily" is the key here. I didn't mean to imply this was the only mechanism of a plate sliding off a bar.
An interference fit between the plates and bar would be obscene - any small change in room temperature would change the level of interference. On warm days, it would be impossible to load the plates. On cold days, it would be a close fit. The plates wouldn't shrink much but the bar would a lot.
If you're interested, check out "freeze fit" or "shrink fit". It's a pretty creative way to not have to hammer pieces into place.
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I answer all my emails: ALewis@StartingStrengthGyms.com
you've never seen a fractured or cracked cast iron plate ?
Rogue came out with those new Made in USA plates, and just used ductile...
They made them a vintage deep dish design for 'reasons' ... maybe the ductile will make the lip hold up better.
They are cheaper than the grey-machined-iron (non-usa) plates they sell.
The cost is really no difference at a certain point when volume is really high.
Especially if its a made is USA plate, the because the bulk of your cost problems are 'merican labor, overhead, profit, admin, quality control costs, etc.