Well I took a previously shot (not by me and number of loading's not known) Star-Line case with a "SMILED", ran it through the LEE FCD as a Pass-Thru Sizer, I wish I would have taken some pictures prior to the sizing and re-loading.
This load was only 7.2 grains of Power Pistol under a Cast Lyman 156 grain Devastator HP, Winchester LP primers, we are talking 40 S&W power level and velocities of 1125 fps as fired from the S&W 1006 5".
Well after examination I found the primer loose & backed out, while looking it over it fell out.
The "SMILE" which re-appeared became very evident again although it was not completely ironed out to start.
Case mouth expanded to 0.4260"
Case body before the smiled area expanded to 0.4300"
Expansion of the SMILE 0.4385"
Extraction rim slightly OVAL min 0.4250" max 0.4290" in-line with the SMILE area.
Primer pocket min 0.2080" max 0.2115" in-line with the SMILE area.
So to those who reload, please inspect your brass thoroughly before you attempt re-sizing, pay attention to the case web areas looking for the dreaded "SMILE" a distinct line where the brass has started to shear at the feed ramp. This is a start of metal shearing. A case Blow Out could occur if this condition is not noticed.
(https://s20.postimg.cc/b517h66qj/proxy.php_image_http_i1086.photobucket.com_albums_j441_The_Sh.jpg)
(https://s20.postimg.cc/o0hk3qrvf/1e4ca8ae-678c-4310-bb9f-7ccbaffab8ee_zps1b1dc64b.jpg)
Here in the case gauge before pass through sizing
(https://s20.postimg.cc/awq54d659/IMG_0895_zpsbabb92ca.jpg)
In the case gauge after pass through sizing, even the primer pocket tighten up some...
(https://s20.postimg.cc/mlu4sc4tp/IMG_0896_zps35ce2f76.jpg)
Just imagine what would happen with a full power 10mm load in this case!
After I fired the first rounds out of my Glock 10mm's I realized that getting an aftermarket barrel was going to be a good idea since I reload. The stock barrel with factory(mild) ammo left quite a bulge at the base of the case. .432-.433. Since getting the KKM barrels, I consistently get .429 with even the hottest loads and no signs of the dreaded "smile".
Ron
Yep...Smiles are just brass that is scrap. Nothing to smile about.
Good test though to illustrate the point for the occasional person who thinks these can just be "ironed out".
Yep! I think I got it lined-up at the 6-o-clock position also because the Smile expanded into the feed ramp and is larger than the normal chamber which usually holds to 0.4280" max on the S&W. Using the "pass-thru" system yields a good look see for the bad brass.
I will say I use mostly used brass, and I work hard during the inspection at each step...this is to help eliminate this condition right here. :o
Yeah.. That is a point. I think lots of guys think the brass is fine once ironed out, because one again you need the perfect confluence of events. Smiled brass, reloaded that happens to line up in the chamber the next time with the shear back at the bottom. If it is at the top, it will probably be fine.
Best not to risk it though.