[LouAvul]

A possible secondary problem is that military brass is thicker than commercial

IIRC, that doesn't impact the outside diameter. Only the inside diameter which, theoretically, raises pressures.

To the OP: do yourself a favor and invest in carbide resizing dies.

[AnAmericanMother]

Yeah, the only place we've had problems with it is flaring the case mouths. I was just thinking out loud.

Clearly the place to go is either (1) lube the heck out of very clean cases or (2) carbide dies.

I have carbide dies for my large volume reloading. The oddball calibers not. I do scrunch an occasional case with those (.455 Webley, .38 S&W and so forth) and it's usually due to failure to get enough lube on the cases.