Which is an outcome of poor gear tooth design?

Poor gear tooth design can lead to increased maintenance needs because it often results in inadequate load distribution and higher stress concentrations within the gear system. This misalignment can cause gears to wear out more quickly, develop issues such as pitting or spalling, and require more frequent inspection and replacement.

Additionally, poorly designed teeth may not engage properly, leading to vibrations and noise, which can further accelerate wear and necessitate more maintenance work to ensure reliability and performance. Addressing these issues often involves more frequent service intervals and repairs, thus increasing the overall maintenance burden on the system.

The other options do not accurately reflect the outcomes of poor gear tooth design, as improved gear synchronization or reduced operating costs are typically not associated with deficiencies in design. Decreased gear size is also not a direct benefit of poor design, as size is generally not reduced but rather dictated by the load capacity and operational requirements of the system.