From the latest remarks it appears clear to me the the problem is an oversize chamber/oversize FL die. The brass is likely expanding in diameter above the head but the sizing die is not reducing the case back to a small enough diameter to fit the chamber. Alternatively the die may be too long/chamber too long, and the die would not be sizing the case shoulder back far enough. If new brass works fine, then the problem is most likely the fault of the resizing operation. Smoke the case shoulder and body, chamber the cartridge, and see where the tight spots are.