Was the piece of brass that stayed in the chamber seated fully forward? If so, it wasn't an OOB (out of battery discharge). I think the fact that the case head is not blown out also indicates it was not an OOBD.
I'm curious about the OP's report of the gross inaccuracy as well as the 10 failures to extract. While certainly not conclusive, those are two pieces of data that I would expect to find in the event that extremely high pressures occurred when he previously fired the handgun.
The high pressure could have been caused by excess powder in the ammunition which, in this case, I doubt because the poor accuracy and FTE occurred with 2 or 3 different kinds of ammunition and at least 10 different rounds. It's unlikely that all of them were overcharged.
It also could have been caused by an incorrectly reamed chamber or one that was right on the "short" limit. If the chamber was short but within SAAMI specs or even shorter and the brass was long but within SAAMI specs or even longer, the tolerance stack would lead to the case mouth not being able to expand enough to release the bullet. The resulting high pressure would result in a catastrophic event.
I think what we have here is a case of the tolerance stack not working in a + & - manor (canceling each other out) but rather all tolerances added up in one direction. The resulting tolerance stack allowed the case mouth to seat far enough past the chamber mouth to create the above catastrophic event. When the case tried to expand it couldn't. I've never used the round the OP refers to and I don't know if it is crimped. However, in his case, crimped or not, his pistol was a ticking time bomb.
The 180 grain Winchester JHP 40 S&W round I regularly use has a heavy roll crimp that is about .060" long; about 1/16". If you apply that much crimp to an empty case and insert it into a chamber, you will see that the case cannot head-space on its mouth. The solution, so they think, is to rely on the bullet diameter to grab the rifling and stop the cartridge just like the case mouth would.
I was concerned when I saw such a heavy roll crimp on the cartridge because the cartridge is designed to head-space on the case mouth. When any case designed to head-space on its mouth is given a heavy roll crimp, it is impossible for it to head-space on its mouth. The ammo manufacturers are concerned about bullet set-back, I'm sure, and thus a heavy roll crimp is seen as a solution. And it is a solution that will work most of the time.
I believe the only way to load any case that head-spaces on the case mouth is to make sure that the case is sized small enough so that normal chambering stresses can not cause bullet setback thus eliminating the need for any crimp except perhaps a slight taper crimp that will still allow the case to head-space normally. Repeated chambering of the same bullet is a different matter.
