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Hi Scot
If your cylinder is a perfect circular shape the shape for your flat top piece will be part of a circle and for the bevelled piece it will be part of a pure elipse. You are finding a teardrop shape because of a lack of circularity.
The attached gives, in red, the developed (unfolded) shapes in 2 cases.
1) where the bevel splits the top of the cylinder in half giving a bevel height of 2.2mm.
The top is a semi-circle and the bevel is half an elipse.
2) where the bevel height is 2.5mm
The top is less than a semi-circle and the bevel is more than half an elipse.
Hope this helps.
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