Hey Steve, how are you testing your bullets, media? I would like to figure out a way to test after trimming meplats or chamfering tips for example to see if it helps expansion.
Later, Leo
The easiest home made test that we have come up with is a 1 gallon milk jug in front of news paper to act at a stop. For us we want to see that the bullet did all of its deformation in the single milk jug. Low vel testing we use reduced loads with TrailBoss powder. Full case of trail boss with most cartridges is pretty close to 1800fps. Problem with the reduced load is having enough stability to keep the bullet nose on. Run the bullet, twist rate, and vel in a stability calc to see if you have 1.5sg or not. Low vel testing is how we figured out that when a bullet is marginally stable it will struggle to deform correctly. When we were putting together our initial line of bullets to go to market we were testing every bullet to ensure that they would function properly below 1800fps. We were using a 10" twist .243 to test our 80g Hammer Hunter. We caught the bullet right at 1800fps and the bullet showed zero deformation. Could have loaded it again. So we decided that we would just find the lowest vel that it would work and publish that as a min for that bullet. We could not get enough TrailBoss in the case to get the vel higher but we had a 6-284 Lap imp on hand that we were building for a customer, so we loaded it up hoping for about a 2000fps impact. Took the shot and again had exatly 1800fps. Thought that was a waste and dug the bullet out to find a perfectly deformed bullet. Difference was the twist. The 6-284 had a 7" twist. Stability with it was over 1.5sg where the stability with the 10" twist was right at 1.2sg. I instantly had flash backs through years of hunting and seeing bullet performance that was "goofy" that I had blamed on bullet construction. Before this test I was always pushing the envelope on stability. Marginal stability was not an issue in my mind if I was getting round holes and shooting sub moa at 1000y.
Tom is correct. Bullets do not hit exactly point on. The less point on the bullet impacts the harder it is to get fluids down into the hollow point. Every bullet needs fluid to get into the bullet and cause it to deform from the inside out. Bullets that have lead all the way out to the nose have an advantage because the lead will act like the fluid. If you look at the hollow point of xxx dia. As you angle the bullet the available size of the hole to accept fluid gets smaller. The smaller the hollow point the more susceptible it is to yaw on impact causing bullet failure. This is why we will not use a hp smaller than 1.5mm in a hunting bullet. They are not as effective and we will not sacrifice terminal performance in order to increase the bc. Rotational vel has very little degradation in flight. It instantly slows down on impact helping to encourage the bullet to wobble thus reducing the available size of the hollow point to accept the needed hydraulics to expand the bullet from the inside out. Think of the bullet as a top spinning. The faster it spins the truer it remains and the more force it takes to knock it off axis. Bullets are no different.
This holds true for a tipped bullet as well. Tipped bullets will have large hollow points but the hole is plugged, requiring the tip to get out of the way so that the hydraulics can enter the hollow point. So unless the tip is of a more robust material than the bullet it will not cause the bullet deform more easily. Once the tip is broken off and allows the fluids into the large remaining hollow point, it will work very well. So tipped bullets have all the same issues plus a plugged hollow point.
So when guys take the time to trim the meplat of a bullet and increase the size of the hp it increases the probability of proper terminal performance even if it is on the marginal side of stability.
Remember that stability calculators give you data for external ballistics (will this bullet fly properly). They do not tell you if your stability is good for terminal ballistics.
I had said earlier that stability for terminal performance should be calculated at sea level even if you are hunting at higher elevation. The higher elevation helps stability for flight characteristics. We have used elevation in our calculations for hunting bullets and seen terminal performance not as good as we expect. The amount of rotational vel needed to overcome the atmospheric conditions and fly well is different than the amount of rotational vel needed to overcome impact and perform terminally.
Through our testing in media and on game, our conclusion is hunting bullets should be considered properly stable for terminal performance, with a minimum of 1.5sg at standard atmosphere at sea level. I can't say that it would solve every problem that is stated in this thread, but I think it would considerably reduce the risk of bullet failure. It does us no good as a bullet manufacture to help people to get bullets from another manufacture to work better, but it's the right thing to do.
Hope I did not hijack
Steve