If you are hedging a long gamma position at volatility that's lower than realized you will be increasing your total expectation of PnL but also increasing variance of the PnL.
Here is a simple example - imagine that you buy an option that's slightly OTM and then decide to hedge it at zero vol. You can imagine that in that case many of the possible paths will lead to PnL of zero, but a big portion will lead to a very high windfall. Alternatively, imagine that you are hedging that option at very high vol - you are not going to be rebalancing your delta frequently enough to make money, but you will be losing money very smoothly.
In a non-theoretical setting (especially for a prop trader who is not judged for his MtM), your hedging frequency, AC of the underlying and many other things will matter more than the implied volatility that you are hedging at.