I noticed the same thing and just gave up on using smoothing groups. 
Randomly does / doesn't work for me. I just use "-smooth" in vrad.
I think the lightmap grids have to line up between the faces in a smoothing group, and even then I don't think they always work. I used them a fair bit when I was working on Echo and they worked very nicely at times, but as has been said they are far from 100% reliable.
yea it has to do with the lightmapgrids. i havent played around much with it yet but i believe that when the edge of the lightmap is directly on the edge of the brush the smooting doesnt work
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