I got out my digital caliper and measured the case dimensions of the 10mm and the .40 S&W.
The 10mm measured .424 at the case head and .421 at the mouth. The .40 S&W measured .421 at the head and .420 at the mouth. That is darn near a straight walled case and I am surprised they feed as well as they do.
It did strike me that the .40 S&W (Both cases were R-P) is slightly smaller and would likely slide down the chamber a little. The extractor would probably keep it from going far but it really does sound dangerous. In fact really dangerous.
Like you, I might try it in a real emergency but nothing short of that.
I don't shoot 10mm regularly, although I have several weapons chambered for it. My primary carry gun is a 9mm, so Im not likely to be in a position to have to depend on substituting a 40S&W for a 10mm.
Just looking at the numbers I don't think three thousandths would be noticeable to anything but the firing pin in relation to servicability. .003 is about the thickness of a dollar bill.
This is assuming that both cartridges have the same bullet in them with the same protrudence. A sloppy or worn chamber on the 10mm weapon would be one place where there could be a more signifigant forward slippage of the .40 S&W that would be noticed.
yarddog, would you measure some fired cases and post the numbers for us?