Well what it comes down to is a chicken and egg problem. UV splits add vertexes and so do hard edges. I've outlined my process for avoiding making a model that takes up too much memory. But in what order do you do it? I can see that the sphere example isn't something I would've encountered since I wouldn't be adding a hard…
I don't have one specific order, i place UV cuts where i need them, harden edges that i need hardened. But if i need to harden an edge that has no UV cut, i also make sure it gets one. I am no big fan of completely automatic solutions that just convert UV seams to hard edges, because that will create hard edges in places…
Any examples? Answer is mostly yes. is it just a generic tiling normal map? the underlying hard/soft edges could be anything - up to your visual discretion. is it a baked unique normal map? Can't just throw hard/soft edges around as it'll break the normal map (normal maps basically are baked out based on your low poly's…