Sounds like fan blower wheel rubbing due to expansion when furnace gets hot.
You will need to disassemble furnace and check for rub marks....motor drives two blowers. One side is combustion wheel and other side is room blower.
Either one could be loose, metal could be warping, motor could be loose/mounted crooked.
Is it time for your medication or mine?
2007 DODGE 3500 QC SRW 5.9L CTD In-Bed 'quiet gen'
2007 HitchHiker II 32.5 UKTG 2000W Xantex Inverter
US NAVY------USS Decatur DDG31