hmmmm.....sounds like that may be it. ya might try a lube like hornady unique or imperial sizing wax. a lil Q-tip of that inside the necks will probably lube better. as a matter of fact, i like the rub on lubes better than the sprays now. it is a lil slow, but works better for me.
i also use a lyman case neck dipper quite a bit. it uses the dry mica powder for a lube.
i've heard of people polishing the expander ball. never tried it, but that may help also.
ideal size die adjustment will let the brass fill the chamber, and stick out of a removed barrel enuff to fill the barrel to frame gap minus .001-.002". you can use a feeler gauge get the barrel to frame gap, n the first one ya close on that will pull out with little resistance is the one.
you can also set the amount of needed brass protrusion from the chamber of a removed barrel with the feeler gauges.
and.....i set my dies off the shellholder a known amount with the feeler gauge. the die setting is always repeatable, or you know what increments you are adjusting up or down to get the proper die setting to make the brass fit that particular frame/barrel combo.
good luck