I would like to understand and learn it myself. And it is still in progress. So it does not make so much sense giving the diameter of filleting. One learning I have in the meantime is trim vs. bool. Here in the attached file I put the banana to the cylinder first with the Trim operation and then the Bool: Union joined together. Filleting with the separated surfaces did not work.

Hi Mala,

re:
> Filleting with the separated surfaces did not work.

It's working for me over here, here is what it looks like:



- Michael

A way to find the problem of fileting here is perhaps a problem in your banana.
If you use SelectNakededges on the banana, you will see a problem with double edges zone.
Perhaps, a problem in the banana's creation ?

Test this one with a reconstruction using loft and blend creation

Yup Phiro is right there is a naked edge on your base model here:


- Michael