Bob: You are mixing issues, and asking 2 different questions. The shape of the ball during flight is not related much to ball size used.
The reason we are concerned about ball diameter/bore diameter, and patch thickness is because of those hot gases pushing behind the PRB as it comes out the barrel. Something has to seal the grooves, as the ball rides on the lands, and is usually smaller than the land( bore) diameter for ease of loading. If the Ball/patch combination does not provide a good seal, the gas cuts and tears the patching, and then melts or " cuts" a part of the ball, distorting its shape and introducing additional drag in the air, which sends the ball off POA.
To some extent, using a filler, or an OP wad of the correct diameter blocks these gases, and allows you to use thinner patching around the ball. This may help in loading a PRB in the barrel quickly, but no real time is saved in total loading time because of the extra step in loading the OP wad or filler. When you can't find the exact patch thickness needed to seal the bore of your gun with the ball diameter you have on hand-- How many of us have searched for this " Holy Grail" for years, driving the ladies at JoAnn Fabrics crazy with our micrometers???-----using an OP wad can at least put you on the range shooting respectable groups. :rotf:
So, the reason we are concerned about ball diameter, and patch thickness has to do with getting the gun to shoot the ball from the barrel, with the gas BEHIND the ball, not around and in front of it. This keeps velocity within a narrower range, for smaller groups, and more accuracy between the POA and POI. Indirectly, if gas does cut a patch because its too thin, the shape of the ball in the air is affected, too. :redface: :shocked2:
:cursing:
I hope that helps to answer your question. I am sure that time lapse photography of RB in the air have been done. I just don't recall where I last saw such pictures in articles.
I have recovered balls fired into water at low speeds( so they don't flatten on impact) and they all show a flattened side for each of the lands in your barrel. If you look very closely at these "flats" you can also see the faint impression of the weave of the cloth patching.
The balls are not " round " as they leave the muzzle of any rifled barrel, if that is what you are wanting to know. The closer the diameter of the ball is to the bore diameter of the gun, the wider the flats seem to be on the fired balls. Even PRBs fired out of smoothbores will obturate, and have a bit of a flat "ring " around the ball where it is pushing against the side of the bore. The obturation comes the push from behind, so if there is a difference in circumference of the ball, its the back half of the PRB that will be " flatter" than the front half of these lead balls fired from Smoothbores.