I have reloaded a lot of .40 S&W range pickups. I've seen a few bulged pieces of brass, but if the bulge can be seen, I discard that case. I have never seen a fired case I reloaded bulge. I reload a 165 gr. Rainier plated FP bullet, and the load develops 1050-1075 over the chronometer; not a maximum load, but no blooper, either. I have a friend who also reloads for .40, and he's never seen any of his bulge, either. We both shoot Glocks.
IMHO, the advice given earlier in this thread is completely sound. Reload only moderate, published loads and you'll have no trouble. I have several other opinions, from reading around on various forums:
1) I think that "pushing the envelope" in .40 is, as one poster so elegantly put it, "bad juju." If you're going to work up hotter loads than those published, do it a tenth grain at a time. This is particularly true for those loading fast powders such as Titegroup or Clays.
2) I think that 155-165 gr. is an ideal bullet weight for .40 S&W. A lot of factory ammo is loaded with 180 gr. bullets; while these factory loads are invariably safe, the 180 gr. bullet derives from loadings for the pappy of the .40, the 10mm, and, in my opinion, is a tad heavy. Attempts to hot up the heavier .401 bullets may be perilous; if you want a 10mm, buy a 10mm.