JRS said:If the rifling were rounded, how would the bullet seal the gases, and engrave the jacket to start the spinning process? In addition to imparting spin to the bullet, the barrel must hold the bullet securely and concentrically as it travels through the barrel. I can't see that occurring with rounded rifling.
Perhaps I didn't explain what I meant by "rounding" well enough. A little searching shows this has and is widely used, and is generically called "polygonal" rifling.
I guess the drawback is as well known as the problem with shooting lead bullets in Glock barrels: With no "slop" in the rifling corners for a slightly oversized bullet (or, equivalently, a regular bullet in a bore shrunken by fouling) to deform, or for overpressure gas blow-by, any overbore bullet results in higher barrel pressures.
Now, for precision shooters, it seems like one would much rather have less deformation of one's bullets and the perfect gas seal offered by polygonal rifling, at the expense of maintaining a clean bore, so I'm still wondering why this isn't the most common rifling for precision barrels.
