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Something is not right at all here. The part about the expander hitting the edge of the case mouth makes perfect sense from an alignment standpoint and “folding” the edge. But now you have that same expander just going into the case with no effect?? Back everything off and unscrew the die. Reinstall it by following their instructions exactly and make sure the lock ring is tight. Try again. I have caught a case on the edge of the sizing/decamp die before but never on an expander die. You have to be waaay off since the tip of the expander is beveled. This is just weird.On some cases it will slide in and on other is like if it's same size.