I've personally never seen a .45ACP become so work hardened that it was unreloadable. Doesn't happen....
When someone reports bullet setback woes I offer three solutions:
--confirm bullet OD
and case sizer ID
and case expander OD
; use good tools (hint: a dial caliper ain't)
--cannelure your cleaned sized cases
--size your fired cases using a LEE 'U' undersized sizing die (I do mostly this).
On a personal note, when I have or have not 'seen it happen', I do not automatically presume it can or cannot happen for someone else, ay?