Bullet - Design

Design

Bullet designs have to solve two primary problems. In the barrel, they must first form a seal with the gun's bore. If a strong seal is not achieved, gas from the propellant charge leaks past the bullet, thus reducing efficiency and possibly accuracy. The bullet must also engage the rifling without damaging or excessively fouling the gun's bore, and without distorting the bullet, which will also reduce accuracy. Bullets must have a surface which will form this seal without causing excessive friction. These interactions between bullet and bore are termed internal ballistics. Bullets must be produced to a high standard, as surface imperfections can affect firing accuracy.

The physics affecting the bullet once it leaves the barrel is termed external ballistics. The primary factors affecting the aerodynamics of a bullet in flight are the bullet's shape and the rotation imparted by the rifling of the gun barrel. Rotational forces stabilize the bullet gyroscopically as well as aerodynamically. Any asymmetry in the bullet is largely canceled as it spins. With smooth-bore firearms, a spherical shape was optimum because no matter how it was oriented, it presented a uniform front. These unstable bullets tumbled erratically and provided only moderate accuracy, however the aerodynamic shape changed little for centuries. Generally, bullet shapes are a compromise between aerodynamics, interior ballistic necessities, and terminal ballistics requirements. Another method of stabilization is for the center of mass of the bullet to be as far forward as is practical, which is how the Minié ball and the shuttlecock are designed. This allows the bullet to fly front-forward by means of aerodynamics.

See Terminal ballistics and/or Stopping power for an overview of how bullet design affects what happens when a bullet impacts with an object. The outcome of the impact is determined by the composition and density of the target material, the angle of incidence, and the velocity and physical characteristics of the bullet itself. Bullets are generally designed to penetrate, deform, and/or break apart. For a given material and bullet, the strike velocity is the primary factor determining which outcome is achieved.

Bullet shapes are many and varied, and an array of them can be found in any reloading manual that sells bullet moulds. Mould manufacturers such as RCBS, Paul Jones Moulds, and David Mos offer many different calibers and designs. With a mould, bullets can be made at home for reloading one's own ammunition, where local laws allow. Hand-casting, however, is only time- and cost-effective for solid lead bullets. Cast and jacketed bullets are also commercially available from numerous manufacturers for hand loading and are much more convenient than casting bullets from bulk lead.