Seven or eight years ago, I had an issue with some bulk M193 ammo blowing primers in a factory AR chambered to accept both 223 and 5.56 ammo and did some extensive testing to determine the cause. A couple of interesting facts regarding case capacity came to light during that experiment:
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Having no reliable means of measuring chamber pressures, I was forced to rely only on visible "signs of pressure" on fired case weighted by muzzle velocity measured via chronograph for a "seat of the pants indication" of pressure. Based solely on these two parameters, a couple of observations regarding case capacity/pressure.
Based on years of reloading, I've noticed that the velocity of a given load is measurably lower in unfired brass than in brass which has been fired one or more times in a particular chamber. Expanding new brass to fit chamber seems to "absorb" some of the pressure, resulting in a slightly lower MV. I would therefore assume ironing out a dented case, even one that had been fired in that chamber, would have a similar effect on pressure.
As far as bullet setback,
some "freebore" can actually reduce pressure and is often used to get maximum MV while holding breech pressures within safe limits. This fact was illustrated during my testing of the M193 ammo mentioned above.
The blown primers in that lot of ammo was resolved by setting the bullets back a few thousandths to provide a bit of "bullet jump" before engaging the rifling. Not sure at what point reduced capacity of the case would outweigh the benefits of freebore, however.
Incidentally, accuracy of that lot of ammo was improved by setting back the bullets, as it improved the base to ogive length, as well.
Regards,
hps