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I recently had a second furnace/ac unit installed in my attic to cover the second floor of my house. The installer only used one air return in my ceiling for the new unit (20x20 grille). The problem is that the large volume of air moving through the grille causes it to "ring". Seems like it is due to the thin metal used. When I remove the grille I can hear the air movement but not the ringing sound. Is there a heavier grille cover made for a situation like this? Thanks,
 

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You know doubt have a "stamp-faced" grille... though it is surprising that a 20 x 20 is humming from a unit sized for your top floor only. How big is this unit?
They do make better grilles... grilles with aerodynamic fins that don't resonate like yours does. I would get a better grille, or ask the installer to put in an additional return, like in the Master Bedroom.
 

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like already ask what size is the unit? if it is a varible speed furnace the fan speeds may not be set correctly. If it is bugging you extremly bad this is not a good solution but you can take needle nose pliers and open up the lovers to a more straight angle the noise will diminish as you open up the grill. This is a bandade to the problem of the grill being too small for the air flow which passes through it.
 
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