Our IT guy, Jay (aka JayChris in the Forum), was having some issues with his .260 AI. A load with known accuracy had suddenly and mysteriously stopped shooting well. Jay couldn’t figure out what was going wrong. Then he remembered he had cleaned his brass using a powerful ultrasonic machine.
He inspected his brass carefully and saw that the ultrasonically-cleaned necks were so “squeaky clean” that he was actually scratching the jackets on his bullets when seating them. As well, Jay noticed that it took more force to seat the bullets and the seating force became less uniform case to case. Jay solved the problem by applying NECO Moly dry-lube inside the necks of his brass before seating the bullets.
The Perils of Ultrasonic Brass Cleaning by JayChris
I rotate my brass so that I can keep track of each firing, so I keep a “clean/ready to load” bin and a “fired” bin. I have 400 pieces of .260 AI brass. So, all of it was on its first firing (after doing a Cream of Wheat fire-forming) until I hit the 400-round mark. To my surprise, things went south at the 500-round mark. The first time I noticed it (according to my range log) was at a match last year, when I dropped several points and had some vertical stringing issues. After that match, I had 400 rounds through the barrel and all of my brass had a single firing on it. So, it was time to clean.
I have used an ultrasonic cleaner for a while now. I recently got a more powerful Ultrasonic cleaner, although I don’t know if that makes a difference. My brass comes out dry and squeaky. Emphasis on the “squeaky”.
I found that my new US machine may have been getting the necks TOO clean. After ultrasonically cleaning my brass, I had noticed that it required a little more force to seat the bullets, but I didn’t really think too much about it. But then, after going over my ordeal with a shooting buddy and going over my process in minutiae, we had an “AH HA” moment when it came to cleaning (he uses good ol’ vibratory cleaning).
So, I used some moly dry-lube to pre-lube the case necks and took some rounds out to test at 200 yards. I used my last known good load and sure enough, the vertical flyers disappeared! I shot two, 10-rounds groups with .335 and .353 MOA vertical dispersion, which is consistent with the results I was originally getting.
Other folks have suggested necks may get “too clean” after ultrasonic cleaning. It was pretty sobering to actually witness, first hand, what can happen when brass is “too clean”. I had read some discussions of issues with neck friction/bullet seating after ultrasonic cleaning, but, frankly, I dismissed the idea. Now I understand. The “too clean” effect doesn’t seem to affect my Dasher at all (perhaps because Dasher necks are very short), but on the bigger .260 AI, it definitely does.
Close-Up Photos of Case-Necks
Here are photos Jay took with a microscope. You can see the difference between tumbled brass and ultrasonically-cleaned brass. Jay says: “Here, in sequence, are the Ultrasound-squeaky-clean case neck, a case neck after treatment with NECO moly dry-lube (you can see the particles that will help coat the neck during seating), and, finally, the neck from a case cleaned with corncob media in a vibratory tumbler. You can clearly see how much smoother the inside of the tumbled neck is. Yes, it’s dirty, but it’s also very, very smooth.
Close-Up of Scratched Bullet
Here is a close-up of a bullet that was seated in an ultrasonically-cleaned (“squeaky clean”) neck, with no lubrication. You can clearly see the damage done to the jacket — in fact, in a couple spots you can see the lead core through the scratches! Jay also observed that quite a bit more seating force was required to seat the bullet in a “squeaky clean” neck.
NOTE: The bullet jacket is naked — NOT coated in any way. It looks a little dark because of the shadow from the microscope lens, and the high contrast.
If you wonder how ammo is made, starting with raw metal, check out this video from Hornady. It shows how bullet jackets are formed from copper, followed by insertion of a lead core. The jacket is then closed up over the core with the bullet taking its final shape in a die (a cannelure is applied on some bullet types). Next the video shows how cartridge brass is formed, starting with small cups of brass. The last part of the video shows how cases are primed and filled with powder, and how bullets are seated into the cases, using an automated process on a giant assembly-line.
At its 100,000+ square foot factory in Grand Island, Nebraska, Hornady produces millions of rounds of ammunition annually. The Grand Island factory is open for tours Monday through Thursday. Hornady Manufacturing, which now boasts over 300 employees, was founded by Joyce Hornady in 1949. The business is currently run by his son Steve Hornady who took over after his father’s death in a plane crash in 1981.
At the end of this year, Berger Bullets plans to introduce a new projectile that may truly be the most revolutionary bullet design since the advent of jacketed spitzers in the late 19th Century. Berger’s new bullet is unlike anything we have ever seen before. It features concentric curved ridges, or “ripples”, on the bearing surface. Tests show that this new projectile, dubbed the “Sonic Ripple Bullet”, has signficantly less drag than conventional bullets (no matter what their ogive configuration). In addition, the Sonic Ripple design provides increased stability at all velocities (allowing barrels with slower twist rates for a given bullet weight).
So, what does all this mean in practical terms? Well, compared to conventional bullets (of similar weight/size), the Sonic Ripple Bullet will shoot a flatter trajectory, buck the wind better, retain energy longer, and remain stable for a much longer distance. That’s big news for competitive shooters, tactical shooters, and long-range hunters.
The Science of the Sonic Ripple Bullet Design
Bryan Litz, Ballistician for Berger Bullets, explains: “This radical leap forward in bullet design was made possible by advanced, new bullet-making technologies. The unusual bullet appearance is only part of the revolutionary ‘Sonic Ripple’ system. The curvilinear waves or ripples in the bullet jacket are designed to create a specific resonance when fired from a specially ‘tuned’ barrel system. The result is an optimization of the sonic wavefront created by the bullet as it travels through its trajectory. This wavefront optimization simultaneously reduces bullet drag while increasing bullet stability.”
In essence, the supersonic shock-wave is smoothed out, dramatically reducing secondary wave fronts. This is all good, as Bryan explains: “If all the internal ballistic requirements are met, the Sonic Ripple bullet exits the muzzle with a harmonically-stabilized launch dynamic. As a further benefit of the ripple design, tests show that the concentric ripples also enhance boundary layer airflow attachment on the bullet. This, in turn, dramatically reduces wake turbulence and attendant drag.”
The reduction of wake turbulence (combined with wavefront optimization) represents a “major breakthrough” which should increase projectile BC by at least 0.14 (on G7 scale), according to Bryan. But, we wondered, might the increased surface area associated with the ripples slow the bullet down in flight? Actually, no. Bryan explained: “Eddies in the boundary layer around the ripples actually lower skin friction drag which more than compensates for increased surface area, resulting in a net friction drag loss at all velocities — both supersonic and transonic.”
Sonic Ripple Bullets Available by the End of 2013
When will we see Sonic Ripple Bullets on dealers’ shelves? Maybe this year. Berger’s marketing department told us: “The Sonic Ripple technology is currently under development and is expected to mature enough for commercial application by late fall, 2013.”
In our article on Bullet Coating we covered the basic principles of applying dry lubricants to “naked” bullets. This article covered the three main coating options: Molybdenum Disulfide (Moly), Tungsten Disulfide (WS2 or “Danzac”), and Hexagonal Boron Nitride (HBN or “White Graphite”). All three compounds can be impact-plated on to bullets with relative ease, using inexpensive equipment. Moly is still the most popular choice, but many more shooters are considering HBN because it is ultra-slippery, it is less messy, and it offers some advantages over Moly or WS2.
After we published our Bullet Coating feature, many readers asked for more info on HBN. Some current moly users had questions about switching over to Boron Nitride. Forum member Larry Medler has published an excellent web article discussing the process of applying 70nm HBN using plastic jars and a Thumler’s rotary tumbler. If you are working with HBN currently, or plan to experiment with Boron Nitride, you should read Medler’s HBN-Coating Article.
After coating some bullets for his 6XC, Medler seems “sold” on the merits of HBN. Larry writes: “The coating process is much better than Moly — no black mess. My coating process times are the same as for Moly. Three hours of tumbling in the corn cob and three hours of tumbling in the steel balls with 3.0 grains of hBN Powder. The bullets look something like sugar-coated donuts when I dump the jar of steel balls with the freshly coated bullets into my sieve to separate. The coated bullets wipe clean to the touch with a little towel rub down and remain very slippery. So far I am very pleased with my coated bullets’ smoothness and appearance.”
Field Tests Are Very Promising
Interestingly, Larry’s HBN-coated bullets are shooting flatter, with tighter vertical, than his moly-coated bullets. Since he has also pointed the tips of this batch of bullets, it’s not clear whether the reduced drop is due to the pointing or the HBN coating, but the results are certainly encouraging: “I have shot the HBN-coated bullets a couple of times now at 600 yards and everything seems to be okay or a lot like Moly. Funny thing is the HBN-coated bullets are shooting higher by 7/8 MOA. I have to check the speed and see if it has changed enough for that POI change. Good news is I had a string of 15 shots with less than 1.5 inches of vertical which is the best I have ever seen with my rifles. Is that due to the hBN or bullet pointing?”
Many of our readers have been interested in learning how modern bullets are made. While a “boutique” bullet-maker, supplied with appropriate cores and jackets, can craft bullets using relatively simple hand dies and manual presses, factory production is different. The major bullet-makers, such as Barnes, employ huge, complex machines to craft their projectiles on an assembly line.
Modern hunting bullets are made with a variety of sophisticated (and expensive) machines, such as Computer Numerical Control (CNC) lathes, giant multi-stage presses, and hydraulic extruding machines that draw lead ingots into lead wire. Barnes offers an “inside look” at the bullet production process in a series of videos filmed at its Mona, UT factory. We’ve embedded four videos from the series here. These videos can also be viewed on the Barnes Bullets YouTube Channel.
Milling Slots in TSX All-Copper Bullet
This video shows how the slots (between the drive bands) in the TSX all-copper bullet are cut. The slots reduce the bearing surface that contacts the rifling. This helps reduce friction and heat, extending the life of barrels used with all-metal, drive-band bullets:
Varminator Bullets Produced in Jumbo Transfer Press
Here is the transfer press used in the production of Varminator and MPG Bullets. The process begins with a giant spool of flat copper material. The copper is stamped into jackets and eventually the formed Varminator bullets are ejected one by one into a bucket.
CNC Lathe Turns Bullets Automatically
In the video below, a Bar-Feed CNC crafts mono-bloc bullets from metal bar stock. Barnes uses a small CNC lathe to turn .50-caliber bullets from brass bar stock. We’re not sure which bullet is being made in this video. The material looks to be sintered metal. In the close-ups you can gold-colored shavings from when the machine was previously used for CNC-turned brass bullets.
Accuracy Testing in 100-yard Tunnel
Barnes regularly tests bullet samples for accuracy. In the video below, a Barnes technician loads sample rounds and tests them for accuracy in a 100-yard tunnel. The rounds are shot through a special fixture — basically a barreled action connected to parallel rods on either side. This allows the testing fixture to slide straight back on recoil (see it move back at 1:07-08 minute mark). Note how the tester actuates the trigger, which is oriented upwards, just the opposite of a normal rifle. The technician taps the upward-pointing trigger shoe lightly with a metal rod. Could this upside-down trigger orientation be useful in benchrest shooting — perhaps with railguns? It could make for an interesting experiment.
Story suggestion by EdLongrange. We welcome reader submissions.
Reloading components are in short supply right now — bullets, brass, powder, primers — you name it. But here’s some good news. Powder Valley Inc. (PVI) has received a huge shipment of Berry’s Mfg. plated bullets. PVI’s president Bryan Richardson said his company now has seven (7) tons of Berry’s bullets in stock, mostly copper-plated pistol bullets. PVI now has Berry’s bullets in all the popular pistol calibers, including: .32 (0.312), .380 (0.356), 9mm, .38/357, .40/10mm, .44 (0.429), and .45 (0.452). PVI also has some Berry’s rifle bullets in stock for: .30 carbine, 7.62×39, and 45-70.
For years, many shooters have coated bullets with Moly (molybdenum disulfide) or Danzac (tungsten disulfide or “WS2″). The idea was to reduce friction between bullets and barrel. In theory, this could lengthen barrel life and extend the number of rounds a shooter can fire between cleanings.
Moly and WS2 both have their fans, but in the last couple of years, some guys have switched to Hexagonal Boron Nitride (HBN), another dry lubricant. The advantage of HBN is that it won’t combine with moisture to create harmful acids. HBN is very slippery and it goes on clear, so it doesn’t leave a dirty mess on your hands or loading bench. Typically, HBN is applied via impact plating (tumbling), just as with Moly.
HBN Results — Both on Bullets and Barrel Bores
Many folks have asked, “Does Hexagonal Boron Nitride really work?” You’ll find answers to that and many other questions on gunsmith Stan Ware’s popular Bench-Talk.com Blog. There Paul Becigneul (aka Pbike) gives a detailed run-down on HBN use, comparing it to other friction-reducers. Paul also discusses the use of HBN in suspension to pre-coat the inside of barrels. Paul observes:
We coated our bullets … how we had been coating with WS2. Now our bullets have a slightly white sheen to them with kind of like a pearl coat. They are so slippery it takes a little practice to pick them up and not drop them on the trailer floor. What have we noticed down range? Nothing different from WS2 other than the black ring on your target around the bullet hole is now white or nonexistent. Our barrels clean just as clean as with WS2. Your hands aren’t black at the end of the day of shooting and that might be the most important part.
Interestingly, Becigneul decided to try a solution of HBN in alcohol, to pre-coat the inside of barrels. Paul had previously used a compound called Penephite to coat the inside of his barrels after cleaning. Paul explains:
If Penephite was used because it was slippery wouldn’t HBN be better? … We called Jon Leist again, and talked to him about mixing HBN and 90% alcohol for a suspension agent to pre-lube our barrels. He though it sounded great but that the AC6111 Grade HBN would be better for this use. It would stand up in the alcohol suspension and cling to the barrel when passed through on a patch. We got some from Jonn and mixed it in alcohol 90%. We use about one teaspoon in 16 ounces of alcohol.
We started using it this fall and what we have noticed is that now that first shot fired out of a clean and pre-lubed barrel can be trusted as the true impact point. We use tuners so now I got to the line, fire two shots judge my group for vertical, adjust the tuner as needed or not, and after tune has been achieved go to my record targets. This use has saved us in time at the bench and bullets in the backstop.
You really should read the whole article by Becigneul. He discusses the use of barrel lubes such as Penephite and “Lock-Ease” in some detail. Paul also provides links to HBN vendors and to the Material Safety Data Sheets (MSDS) for the various compounds he tested.
The better, up-to-date ballistics programs let you select either G1 or G7 Ballistic Coefficient (BC) values when calculating a trajectory. The ballistic coefficient (BC) of a body is a measure of its ability to overcome air resistance in flight. You’ve probably seen that G7 values are numerically lower than G1 values for the same bullet (typically). But that doesn’t mean you should select a G1 value simply because it is higher.
Some readers are not quite sure about the difference between G1 and G7 models. One forum member wrote us: “I went on the JBM Ballistics website to use the web-based Trajectory Calculator and when I got to the part that gives you a choice to choose between G1 and G7 BC, I was stumped. What determines how, or which one to use?”
The simple answer to that is the G1 value normally works better for shorter flat-based bullets, while the G7 value should work better for longer, boat-tailed bullets.
G1 vs. G7 Ballistic Coefficients — Which Is Right for You?
G1 and G7 refer both refer to aerodynamic drag models based on particular “standard projectile” shapes. The G1 shape looks like a flat-based bullet. The G7 shape is quite different, and better approximates the geometry of a modern long-range bullet. So, when choosing your drag model, G1 is preferrable for flat-based bullets, while G7 is ordinarily a “better fit” for longer, boat-tailed bullets.
Drag Models — G7 is better than G1 for Long-Range Bullets
Many ballistics programs still offer only the default G1 drag model. Bryan Litz, author of Applied Ballistics for Long Range Shooting, believes the G7 standard is preferrable for long-range, low-drag bullets: “Part of the reason there is so much ‘slop’ in advertised BCs is because they’re referenced to the G1 standard which is very speed sensitive. The G7 standard is more appropriate for long range bullets. Here’s the results of my testing on two low-drag, long-range boat-tail bullets, so you can see how the G1 and G7 Ballistic coefficients compare:
G1 BCs, averaged between 1500 fps and 3000 fps:
Berger 180 VLD: 0.659 lb/in²
JLK 180: 0.645 lb/in²
The reason the BC for the JLK is less is mostly because the meplat was significantly larger on the particular lot that I tested (0.075″ vs 0.059″; see attached drawings).
For bullets like these, it’s much better to use the G7 standard. The following BCs are referenced to the G7 standard, and are constant for all speeds.
Many modern ballistics programs, including the free online JBM Ballistics Program, are able to use BCs referenced to G7 standards. When available, these BCs are more appropriate for long range bullets, according to Bryan.
[Editor's NOTE: BCs are normally reported simply as an 0.XXX number. The lb/in² tag applies to all BCs, but is commonly left off for simplicity.]
Here’s good news for purchasers of reloading components. Powder Valley Inc. (PVI) is “holding the line” on prices of powder, primers, brass, and bullets. In so doing, Powder Valley is “keeping the faith” with its customer base. By contrast, many local gun shops and big box retailers have jacked up prices on guns, ammo, and reloading supplies in response to a spike in demand. With the hue and cry for new gun control legislation, gun owners have rushed to stores to get guns, ammo, and reloading components. Predictably, some retailers have raised prices on everything from primers to all types of semi-auto firearms. Not so with Powder Valley. If you check the PVI website, you’ll see that prices for almost all products in stock are basically the same as a month ago (before the events in Newtown). Unlike some other vendors, Powder Valley has refrained from ramping up prices. We commend PVI for this.
Here is what Powder Valley owner Bryan Richardson told us about his company’s pricing policy:
“We watched back in 2009 as companies jacked up their prices due to supply and demand. This may make sense for some retailers and manufacturers. However, this is not the way we do business, nor will ever do business. It is completely against our conviction.
My wife and I established our business in 2000 with a mission statement of: ‘Providing the finest in reloading components and other shooting sports related products at the best possible price. In doing so, we will conduct business with the utmost respect and consideration for the customer’s needs by constantly demonstrating honesty and integrity.’
Therefore, increasing prices due to current market and political conditions is contrary to our mission of conducting business with the utmost respect and consideration for the customer’s needs. It is my opinion that if we want our industry to survive… we cannot price consumers out of shooting. Therefore, when you see our prices increase or decrease it is simply based off of the manufacturer’s or importer’s pricing. I think history shows that consumers remember the companies who elevated their prices for short-term profits and those who did not. We are here for the long haul and want to grow our business through building our customer base, not increasing our prices.”
This article originally appeared in Sinclair Intl’s Reloading Press Blog, which is chock full of informative articles and interesting videos. CLICK HERE to check out the Reloading Press.
Steps to Minimize Bullet Run-Out
by Pete Petros, Lead Reloading Technician, Sinclair International
Poor bullet run-out can cause poor and inconsistent accuracy, and variations in bullet velocities. The truer the loaded round, the more consistent your results will be on paper and across the chronograph.
Measuring Concentricity
We all know that low run-out is the goal. But how can you tell if your run-out is high or low? Run-out is generally measured in thousandths of an inch with a concentricity gauge. There are many concentricity gauges to choose from that work well. Some work on loaded rounds only, some have a bullet straightening feature, and a few work on both loaded rounds and empty cases for checking case neck concentricity. The tool of choice for the Sinclair Reloading Tech Staff is the Sinclair Concentricity Gauge (Part # 09-175).
This tool is a mainstay on my bench, and it is used about as much as I use my reloading press! The tool uses two sets of bearings that are set on lateral, length-adjustable anodized aluminum blocks to accommodate cartridges from .221 Fireball-sized cases up to .50 BMG. The indicator is set on a height adjustable swiveling base on a stand that can be used for checking bullet or case neck run-out. The adjustable blocks ride aligned in a precision-milled slot. The entire set up is on an anodized base plate that gives excellent support during the process that is crucial to operation and accuracy. Basically the operation consists of placing a loaded round (for checking bullet run-out) or an empty case (for case run-out) on the bearings with the indicator end touching the chosen point to be measured. The case is easily spun with one finger as the indicator measures the amount of run-out. Once this process has been done a few times it is a fast and accurate means of measurement. In terms of indicator type being used, whether dial or digital, I actually prefer a standard dial indicator over the digital type. My reason for this choice is that you can see the needle jump when run-out is present. I believe this to be easier and faster than looking at digital numbers while measuring. In the video below, Sinclair’s Bill Gravatt shows how to use the Sinclair Concentricity Gauge correctly.
Sizing Steps to Minimize Run-Out
One of the most common steps in the reloading process that contributes to bullet run-out occurs is the sizing operation. If improper techniques are used or there are issues with the sizing die set up, a once perfectly concentric case can become out of whack. By using the proper dies for your application, properly setting up the die/shell holder or floating the de-capping/expander assembly, you can eliminate problems before they happen.
Many of us on the technical staff choose the Redding Type-S series of dies. These are full-Length or neck sizing dies that utilize a removable/changeable neck bushing (sold separately) to size the neck according to your application. These dies are machined with true precision and quality in mind. The Type-S dies come with a standard de-capping assembly with a caliber-specific expander ball in place. In addition to this an undersized retainer to hold the de-capping pin is included with the die. In my experience with these dies I use the standard expander ball with new, unfired brass on the initial re-size. I will then use the undersized retainer in place of the expander ball with brass that has been fired. I have found this step crucial in my reloading regiment to minimize bullet run out. The use of the expander ball can cause a few thousandths of run-out when the case is being pulled back out of the sizing die. With the undersized retainer in place the only thing that touches the neck of the case in sizing is the bushing. If you prefer to use an expander ball, Redding offers caliber specific carbide floating expander balls that fit on the de-capping rod. This free floating expander ball will self center on the case neck, and reduce the amount of run-out that can be caused by a standard expander ball.
When setting up a Type-S sizing die, set the neck bushing into the die with the numbers facing down toward the body of the die. Tighten the de-capping assembly until it contacts the bushing and then back it off ¼ of a turn. This allows the bushing to free float in the die. You should be able to hear the bushing rattle if you shake the die. Having the bushing free floating self centers the neck, and again minimizes any run-out that can occur.
If you prefer other brands of sizing dies there are a few tricks that people use to minimize run-out as well. Many reloaders claim that the use of an O-ring at the base of the de-capping assembly lock nut will float the assembly and help self center during sizing. Another trick that has been used is to remove the retaining pin on the shell holder slot on the press ram, and use an O-ring in its place to hold the shell holder in place. This allows the shell holder to self center during sizing as well.
Seating Steps to Minimize Run-Out
Run-out issues can arise during the bullet seating process. To reduce run-out during seating, use a high-quality die with a sliding sleeve. The sliding sleeve perfectly aligns the case with the bullet to be seated. Good examples of these dies are the Redding Competition Micrometer bullet seating dies, Forster Ultra Seaters, or RCBS Competition Seating dies. All of these dies utilize a micrometer top to precisely set seating depth. They are all very high quality dies that have tight tolerances to maximize bullet straightness during seating.
We receive many questions about seating long pointed bullets such as the Berger VLD or Hornady A-Max. One problem that the reloader faces with longer bullets is that they are so long that the standard seating stem is not machined deep enough to contact these bullets properly. The point of the bullet “bottoms out” in the stem and the result is off-center seating and/or rings and dents on the bullet nose. If you plan on using such bullets, you should purchase a “VLD” style seating stem, which is cut to accommodate the longer bullets. The use of this stem results in truer seating of the bullet without leaving a ring or marring the tip of the bullet.
Besides using a traditional press and threaded seating die, another great way to get a true bullet seat is by using an arbor press and Wilson chamber-type seating die. These dies are cut to very tight tolerances and have proven themselves as the main choice for bench rest enthusiasts. The design of the die positively aligns the case with the bullet as they are both captured by the die before the bullet is pushed straight into the case by the stem. These seating dies are available with the standard seating cap and stem or an additional micrometer top can be added for precise adjustment. Wilson also offers a stainless seating die with an integral micrometer seating head.
Finally another trick used by many in the seating process is to turn the case while the bullet is being seated. Some people claim this will keep things straight. What they do is raise the ram in increments while seating and rotate the case in the shellholder in increments of 90 degrees from the original starting while the bullet is being seated. Personally I have tried this and have seen no significant difference at all. However you may be the judge of this one. It makes sense, and maybe I should try this a little more before I rule it out.
After the Rounds Are Loaded — Batch Sorting by Concentricity Levels
No matter how meticulous you are, and no matter how good your components and tools are, run-out will still show up. Reloaders can drive themselves crazy trying to make each and every loaded round a true “0” in run-out. You will still see some minimal amount no matter what you do. Set yourself a standard of maximum allowable run-out for your loads. For instance for my Long Range 600- and 1000-yard F-Class loads I like to see .002” or less. I average .0015” and see a few in the range up to .004”. I spin each loaded round on my Sinclair Concentricity Gauge and sort them by run-out. Those that run over .002” I use for sighters or practice. Though achieving zero run-out (on every round) isn’t possible, minimizing run-out can definitely help your performance. Not only will your loads shoot better but you will have one less thing to worry about when you are lining up the sights on the target. — Pete Petros
Ruprecht Nennstiel, a forensic ballistics expert from Wiesbaden, Germany, has authored a great resource about bullet behavior in flight. Nennstiel’s comprehensive article, How Do Bullets Fly, explains all the forces which affect bullet flight including gravity, wind, gyroscopic effects, aerodynamic drag, and lift. Nennstiel even explains the rather arcane Magnus Force and Coriolis Effect which come into play at long ranges. Nennstiel’s remarkable resource contains many useful illustrations plus new experimental observations of bullets fired from small arms, both at short and at long ranges.
Shadowgraph of .308 Winchester Bullet
A convenient index is provided so you can study each particular force in sequence. Writing with clear, precise prose, Nennstiel explains each key factor that affects external ballistics. For starters, we all know that bullets spin when launched from a rifled barrel. But Nennstiel explains in greater detail how this spinning creates gyroscopic stability:
“The overturning moment MW tends to rotate the bullet about an axis, which goes through the CG (center of gravity) and which is perpendicular to the plane of drag, the plane, formed by the velocity vector ‘v’ and the longitudinal axis of the bullet. In the absence of spin, the yaw angle ‘δ’ would grow and the bullet would tumble.
If the bullet has sufficient spin, saying if it rotates fast enough about its axis of form, the gyroscopic effect takes place: the bullet’s longitudinal axis moves into the direction of the overturning moment, perpendicular to the plane of drag. This axis shift however alters the plane of drag, which then rotates about the velocity vector. This movement is called precession or slow mode oscillation.”
Raise Your Ballistic IQ
Though comprehensible to the average reader with some grounding in basic physics, Nennstiel’s work is really the equivalent of a Ph.D thesis in external ballistics. You could easily spend hours reading (and re-reading) all the primary material as well as the detailed FAQ section. But we think it’s worth plowing into How Do Bullets Fly from start to finish. We suggest you bookmark the page for future reference. You can also download the complete article for future reference and offline reading.
Barnes Bullets has produced some videos showing the processes used to make Barnes’ popular TSX (all-copper), Match Burner (lead-core, copper jacket), and Varmint Grenade (copper jacket, powdered metal core) bullets.
Drawing Copper Wire for TSX Bullets
The first video features the TSX. These all-copper bullets start by drawing and cutting solid copper wire into slugs. The material is first drawn down to the correct diameter and then cut to the proper weight on a large industrial shear press. Great care is taken to ensure the most consistent weight possible. The machines are checked frequently. The video below show how copper wire is sized (in the first black box on the green machine) and then travels over a series of rollers to the cutting station.
Extruding Lead Wire for Bullet Cores
The second video shows the extrusion of lead core material for Barnes’ Originals and Match Burner bullets. First, soft lead is melted into 16″ long by 2 ½” round ingots. The ingots are then fed into a large steel tube and hydraulically forced through a cone at about 3500 psi, producing lead wire. This extrusion process makes the lead wire to the correct diameter. The lead wire is then fed into a cutter that chops it into the correct weight. After cutting, the lead cores are sorted and again fed into the bullet presses.
Powdered Metal Mixing for Varmint Grenade Bullets
The third video shows the mixing of metal for the composite cores in Varmint Grenade bullets. This powdered metal core is one reason why Varmint Grenades fragment so explosively on impact. The core for these bullets (identical to the MPG bullet) is made from a very fine copper and tin powder. After mixing, the metal powder matrix is fed via the hopper into the Fetta press. This machine then feeds the powder into a chamber where it is compressed into a solid core that can be put into a copper jacket. In the video, the powdered metal is fed into the machine on the left. It’s a bit difficult to see, but there is a bottom punch that matches each top punch. The two punches come together to form the core.
This is a very expensive, high-output machine. Fully tooled and set at a reasonable speed, it can make upwards of 90,000 cores per hour!
Story Tip by EdLongRange. We welcome reader story ideas.
Our IT guy, Jay (aka JayChris in the Forum), was having some issues with his .260 AI. A load with known accuracy had suddenly and mysteriously stopped shooting well. Jay couldn’t figure out what was going wrong. Then he remembered he had cleaned his brass using a powerful ultrasonic machine.
I have used an ultrasonic cleaner for a while now. I recently got a more powerful Ultrasonic cleaner, although I don’t know if that makes a difference. My brass comes out dry and squeaky. Emphasis on the “squeaky”. 
If you wonder how ammo is made, starting with raw metal, check out this video from 
The Science of the Sonic Ripple Bullet Design
In our article on 
Many of our readers have been interested in learning how modern bullets are made. While a “boutique” bullet-maker, supplied with appropriate cores and jackets, can craft bullets using relatively simple hand dies and manual presses, factory production is different. The major bullet-makers, such as 
The better, up-to-date ballistics programs let you select either G1 or G7 Ballistic Coefficient (BC) values when calculating a trajectory. The ballistic coefficient (BC) of a body is a measure of its ability to overcome air resistance in flight. You’ve probably seen that G7 values are numerically lower than G1 values for the same bullet (typically). But that doesn’t mean you should select a G1 value simply because it is higher.
Drag Models — G7 is better than G1 for Long-Range Bullets
Here’s good news for purchasers of reloading components. 
Measuring Concentricity
Many of us on the technical staff choose the Redding Type-S series of dies. These are full-Length or neck sizing dies that utilize a removable/changeable neck bushing (sold separately) to size the neck according to your application. These dies are machined with true precision and quality in mind. The Type-S dies come with a standard de-capping assembly with a caliber-specific expander ball in place. In addition to this an undersized retainer to hold the de-capping pin is included with the die. In my experience with these dies I use the standard expander ball with new, unfired brass on the initial re-size. I will then use the undersized retainer in place of the expander ball with brass that has been fired. I have found this step crucial in my reloading regiment to minimize bullet run out. The use of the expander ball can cause a few thousandths of run-out when the case is being pulled back out of the sizing die. With the undersized retainer in place the only thing that touches the neck of the case in sizing is the bushing. If you prefer to use an expander ball, Redding offers caliber specific carbide floating expander balls that fit on the de-capping rod. This free floating expander ball will self center on the case neck, and reduce the amount of run-out that can be caused by a standard expander ball.
Barnes Bullets has produced some videos showing the processes used to make Barnes’ popular TSX (all-copper), Match Burner (lead-core, copper jacket), and Varmint Grenade (copper jacket, powdered metal core) bullets.
