I don't know when the term Cylinder came into use to denote no choke. It was unlikely to have been used on muzzleloaders because all muzzleloaders were the same, the concept of the choked barrel didn't arrive until the late 1860's, early 1870's when breech loaders were taking over and muzzleloaders were fading from use. The early and increasing use of choke led to great confusion for gunsmiths and makers when measuring barrels so the English proof marks were changed in 1875 to indicate choke if present. Using different markings this continued until fairly modern times.A choke tube bore is slightly larger in diameter than the barrel inner diameter, where it contacts the inner shoulder of the choke tube threaded recess.
Bad things happen to choke tubes if a projectile collides with or gets under the thin skirt of the choke tube. This is why you make sure your choke tubes are tightly threaded in.
A choke tube that has the same or slightly less exit diameter as the bore diameter is called cylinder. The origin of the term may go back as far as muzzle loading shotguns, which originally had no choke.
Yes, the rear lip of a choke tube where it contacts the barrel body needs to be slightly larger than the bore diameter to prevent the outer edges of the shot charge from striking it which would disrupt the pattern. This manufacturing tolerance is often about .010" on guns that are made with care and precision, not all guns are.
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