To the OP, We got off tract a little with a lot of decussion about the muzzle brake, but it was part of the question.
On your velocity drop, I think it was caused buy your change in the loading process. You mentioned changing the neck sizing bushings, and that Is where I would first look because changes in case neck
tension can effect the burn rates of powder and effect velocity and SDs. Any changes from your tested load (Sizing, case brand, Primer, Powder lot, ETC)could cause this.
On the baffle shape/design question, The shape definitely has an effect on gas flow and effectiveness
which one is the best ? Only testing on a flow meter, using the same load and the same port volume would effectively show which flowed the best.
The best comparison I can think of is a racing engine, When building a high performance engine one of the first thing we do is grind/machine any sharp corners our (Radius) and polish the surfaces of the manifold and the heads to improve flow. then we also volume match each port so they flow the exact same amount of gas to improve performance. With muzzle brake pressures being much higher than engine pressures finish is all the more important.
Shape does have a bearing on the total performance of the brake but so does the finish inside the brake, volume based on the cartridge, and the matching volume of each port to balance the load placed on each port and prevent an imbalance of effect from an opposing port.
If you see more erosion or carbon near/at the rear port, it is doing most of the work and losing efficiency. While testing, we found that many of the brakes had scaring and carbon in the first port
(Nearest the barrel), And with slow motion Video you could see most of the fire coming from that port. the other ports were not contributing to there share of the recoil reduction.
A well made, well balanced and sized brake will manage the gases equally and distribute fouling equally. While looking at slow motion Video/film watch the fire coming out of the brakes. Some designs have most of the fire coming out of the front of the brake. This is recoil that has not been
taken away. some other brakes show the first port doing most of the work, losing efficiency. a Well balanced and tuned brake will show each port lit up the same with little fire coming front the front of the brake.
J E CUSTOM