LRC, until the brass is fireformed, it is not consistent in exterior size even from the same lot. This is because brass gets bang around during shipping and distorted. Even running through a sizer doesn't help so I always COW fireform before I bother with any other steps.
If the chamber is properly cut and headspace/lock up is tight (BR tight), a fired case has no where to go (why BR rifles have brass that lasts longer then the barrels). Expansion is limited by the chamber dimensions. Any case with any bulges or irregularities indicate a poorly cut chamber or a lock up that is loose/spongy. The case indicates a hardware problem. Improper sizing can also lead to these types of problems.
From the way brass is manf, the chances of really out of whack brass isn't that high these days (why Win brass is dominating many forms of LR shooting). Of course, 'BR' prep eliminates that even further to near perfection. I don't see brass as being a huge source of inaccuracy.
The two biggest variables we don't control are the parts that make the bang happen. Yep, the powder and primer. Now that top level shooters are using real monitoring equipment, they are finding all sorts of interesting details about this.
Powders are varying huge amounts from lot to lot as are primers. In the big scheme of things, they are very small but when you are looking for single digit variances and bughole groups at 2/3 of a mile, it matters.
Read a most interesting article where a brand of match primers were shown to cause all sorts of pressure and velocity issues. The lot before was perfect, another lot was fine. That 'bad' lot almost caused this top US shooter to pitch barrels on all his rifles (thought they were worn out) if not for his measuring equipment.
Bullets are another huge variable. With different types of sorting, even match bullets are showing difference up to 'cull' 50%. Not so match after all.
So for me, I still let the paper tell the tale. If I see trends or flyers that are way off, I start to diagnose the problem. As to sorting brass, I find the best way is to sort during shooting. Any shot that is a flyer gets marked, if it throws the shot again, the brass is destroyed.
If it doesn't and other brass does, diagnose the shooter, rifle, other components. Might just be that the problem lies in the primer or powder or bullet.
That way I have eliminated all the variables and have brass/ammo as good as I can make it.
As to how I know extractor grooves aren't manf the same, simple. The brass doesn't fit the Lee hand primer shellholder the same. Some are loose, others are tight. All shoot into the same teeny tiny group. Same lot and number of firings.
I use brass from the same lot and brand. Deburr the flash hole (might look at drilling them all the same in the future depending on testing). COW fireform. Collet neck size. Trim. Chamfer necks. Load. I rarely check case volume anymore as it is rare to find a case that isn't the same volume from the same lot of brass.
Watch case runout and case hardening (anneal if needed).
Sorting during fire also allows one to use once fired brass. With a bit of sorting, it can work as well as any 'bagged' brass.
Jerry