Steve, first of all, I dont know if your rasp is an old one or a new one and even if I did, I dont know what steel it is, for sure. Some new files are case hardened low carbon. But let's assume it's high carbon.
This is just a suggestion of what might be happening. There may be some carbon loss on the edge and you might "read" it as being soft. If you file back a couple of good strokes, it might be hard. In this case you would have to allow some extra material to be removed to reach the hardened material. This will take place more when the piece has been in and out of the fire a lot during the forging procedure. Lots of heats.
When using an unknown steel, you are also having to accept some other "unknowns" that follow. Such as, Which is the proper quenchant, drawback temperatures, etc.?