burn rates under pressure are worse if the substance is sensitive to pressure. look at different oxidizers and thier burn rate exponent, (*hint*) - trying to keep the mods off my post... but your oxidizer is certainly part of the burn rate, and more importatnly in this case burn rate exponent.
your 84mm is around 3.3125" which for your diameter would produce a progressive burn. This in turn may have induced some erosive burning.
both of these increase burn rates.
small airpockets in the propellant i make is no concern and doesnt increase burn rate. maybe a minor and mostly temporary difference in burning surface area. might make the motor sound "dirty" when it burns. but overall is a small percentage change.
from what i think i know about your propellant, is that they would be fairly airpocket sensitive, and rapidly overpressurize if it occured.
Would casting 4 grains or 3 be a better route to illiminate air pockets or would tat increase the burn again?? A smaller nozzle would increase chamber pressure = to higher burn rate wouldn't it
what your talking about, is KN the burning surface area in ratio to the throat area. Here is one of the best documents I found early on, and gave me a clear understanding of how making a nozzle smaller in diameter, may not work so well to increase the KN. since it has an exponetial effect on Cp
https://thrustgear.com/topics/Kn_Notes.htm
I usual increse the core diameter, or add grains (end grain surface) to up my kn. making a smaller nozzle, comes after you understand the pressure exponent fully for the propellant.
I would suggest, using the bates geometry formula to find the most neutral bates configuration(listed in that kn guide) fire a low end KN range, then middle, then higher. based on diffrent nozzles. if you have a way to measure the thrust or Cp, you then can determine the burn rate exponent of your propellant.