We have no substance that can accurately equal the bone and tissue of a live animal. Not even ballistic's Gel, commonly used as a test medium duplicates a bullet's performance in living flesh well. But its close. Everything that will allow a bullet to penetrate has been used as a test medium. My first testing was into the ground, and we then dug the bullets up with pocket knives. Later, we used a stump from an American Elm tree that had been cut down at our house. I have used dry wall, sand bags, dry paper, wet paper, wood- solid, spaced, plywood, and standard pine lumber.
Since you can't get any medium to exactly duplicate living tissue, all you can do is COMPARATIVE testing. You use a known load that has been written about by someone with ballistic's gel, or who has killed a deer with that load, and you shoot it into your test medium of choice, and measure how much penetration you get. That becomes your standard, and the basis for an equation to use in determining in reverse how much another load and ball, penetrating " X " distance in your test medium would penetrate in a live deer, based on the performance reported by the other shooter using that load to kill his deer.
Lets use as an example a story that someone with a .45 cal. longrifle uses .60 grains of FFFg powder in his percussion ignition gun to kill a deer with a broadside shot. The ball breaks a rib entering the body, goes through both lungs and exits betwee two ribs. The measure distance of that penetration is 8 inches. You have a .45 and load it with the same load, which give you 5 inches of penetration in wet newspaper bundles tied together. So, 60 grains in your wet newspaper bundles goes 5 inches by comparision to the same load going 8 inches through a deer while breaking a rib on entry.
Now, you want to test a .54 caliber round ball load. You load 80 grains of FFFg and shoot it into your test medium. The ball travels 6 inches, and mushrooms to more than 1 inch in diameter. comparing the test of the .54 to your .45 testing, the .54 still penetrates further than your .45 bullet did, so you have no doubt that it will completely penetrate a deer and then some. 5:8 vs. 6:8. It gets trickier to put your faith in when the larger ball penetrates LESS in your test medium. Lets say because you have an old shoulder injury and are particularly sensitive to recoil, you decided to use FFg powder, and reduce the charge to 60 grain, a good target load, but not a bone crushing hunting load. Now, in your test medium, the ball only pentrates 4 inches. Will it still kill a deer? Yes, of course it will. Penetration is more more correlated to the weight of the projectile, particularly with round ball, than with velocity. If that .54 RB penetrates 4 inches of wet newspaper at 50 yds, it will easily penetrate a deer at that range. Your test medium is much more " solid " than deer flesh. Remember, the .45 load penetrated 8 inches of deer when it only penetrated 5 inches of your test medium. That is a 5:8 ratio for the comparison between the two media.
4 inches of penetration compares to the deer medium as 6.4 inches.( 4 x 8 divided by 5 = 6.4 ), Giving you actually deeper penetration than you got with the .45 caliber load, which was only 5 inches.
So use whatever test medium you have handy.
I used 1 ich board lumber( actually cut 3/4" thick in America) spaced 1 inch apart. With my .50 cal. RB target load of 60 grains, the ball penetrated 6 boards and smacked into the 7th! I upped the load to 100 grains, and that ball went through 6 boards and barely stuck, flattened, to the face of the 7th board, but fell off as soon as I touched it. The aditional VELOCITY did not give me any more penetration. The additional powder did not give me more penetration, because the two balls shot weighed the same. Even the backside of each board was examined to see if there was a discernible difference in the damage shown between the two balls, and no general conclusion could be made. Both balls flattened quite fully, and were ragged pieces of lead when they stopped.
Later I found that on a 100 yd. range, I got slightly more accurate and a flatter trajectory using 70 grains of FFg. I later took a large deer at about 35 yds with that load in my .50 cal. rifle. It broke a rib going in, and another going out, taking the lungs, and some of the major blood vessels above the hear on its way through. She stumbled to the bottom of the ravine and died there.
Just remember that the larger the caliber of gun you use, the heavier the ROUND BALL, and it penetrates farther even at lower velocities than a smaller caliber RB will do, all other things being equal. At the short ranges where most deer are shot, there is no need for shoulder-breaking loads. The added velocity only affects the trajectory, and at short range the trajectory is not a problem, anyway.