I tried to replicate your case:
i followed two ways:first i used FLOW tool to transfer rectangular grips on cylinder(red)
second i just placed rectangular grips on the cylinder using POLAR ARRAY tool (green)
here on top wiew:
you can see difference: FLOW tool make a "distorsion" on rectangular grips when flowing
doing a close-up you can see different angles
second (green) give a better condition to the FILLET tool to work...more "opened"...
i tried to fillet flowed grips after BOOL-UNION only with a small radius,but not enough
filleting green placed grips after BOOL-UNION gave more chances
i used G2 Fillet 1mm radius,i did a lot of grips so the file is too heavy to post (100 Mb more or less)
selecting all and do the Fillet in one stroke require too much time for calculation so here,on picture, i just select 6 grips,as you can see
hope that Michael or someone else can explain better than me what i tried to show
M
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