Back in the day, before I retired, I ran ( owned) a Landscaping company. I had about 20 saws, a few of which were the same, except for the bar(s). Small stuff? grab the 14 inch bar. Bigger stuff? Grab an identical saw with a 20 inch bar. Smaller bars always seem to cut quicker, due to less power loss pulling the chain.Yes, my question was about tuning the carb, so the assumption was that bar and chain were on.
As for the rest, someone more experienced will hopefully chime in, but my understanding is that you should retune when any of the following change: altitude, ambient temperature, oil/gas ratio, kind of oil, kind of gas, length and type of bar/chain. I mean this is probably overdoing it; I've definitely tuned for one bar length and merrily switched out to a longer bar and no issues. But if you're alaskan milling (like I am) I think you have to be a lot more careful. Crosscutting for firewood is a lot less load, so more forgiving.
You had two identical saws with different bars? Why not just have one saw and switch out the bars?
Truthfully, I never re-tuned for a bar change.. It never crossed my mind to do so. It's also pretty flat where I am, not enough change in elevation to have to worry about altitude. I usually just pull the thingy over to the Winter setting in the carb, to prevent icing when it's cold outside.
As I always run the same oil and gas, at the same ratio, I seldom even think about re-tuning the carb. 91 Octane Ethanol free Premium, and 70 to 1 Amsoil Saber.
I Alaskan mill with an old school Stihl. I never changed the carb settings, when I purposed it for milling. Same fuel and mix as the rest of the crew. It truly didn't seem to mind at all. But I might think about putting in a touch more Saber into the tank.. A fouled plug is way cheaper than a new top end.