Adam
Small errors can drive you nuts.
Assuming sufficiently parallel stock of sufficiently consistent diameter with randomly distributed variations the sliding fingers of a Multisize collet are fully constrained when tightening if both sides of the finger are in full length contact with the closing cone and the stock. Full constraint is necessary for a meaningful and repeatable specification of accuracy. When a perfect collet is tightened down onto perfect stock all forces are in balance with constant loading along the length of the fingers. In this case any error is, theoretically, due to manufacturing tolerances in both collet, its holder and the stock and the results therefore quantifiable.
If the stock is shorter than the fingers the back, unsupported, end of the fingers are in the wind with no compression forces from gripping the stock. Hence the forces are out of balance. Depending on the exact interaction between manufacturing tolerances and the force variation along the finger the nearest approach to force balance may be with the stock slightly out of line. For obvious reasons this is totally unquantifiable as the error is emergent, not deterministic.
Of course any residual out of balance forces need to be absorbed in the finger itself. Which is clearly less than ideal. They are not designed to deal with that. Unlike a chuck jaw which, up to a point and with appropriate care, is. Whether such use actually results in damage must, in the general case, be unknowable. Obviously the shorter the length of stock held the worse the situation but defining where the line between "naughty but OK this one time" and "flagrant abuse" falls is impossible. So Burnerd have to say "Don't do it." Clearly 10 thou short is neither here nor there but having only 1/4" of stock in the collet isn't going to fly. Well actually it might literally fly when tool hits work.
Clive
PS Dennis Turk, SouthBend Guru, lathe restorer extraordinaire and all round good guy was wont to say "Everything is made of rubber. Maybe stiff rubber. But still rubber."
Edited By Clive Foster on 18/04/2020 21:12:03
Edited By Clive Foster on 18/04/2020 21:12:22