It appears that you've got some internal transmission gear issues, and a situation similar to my wife's mixer, which we got new in Dec 2006. It could be as simple as the gears have become loose and are making different contact, hence the noise. The higher the speed, the louder, higher pitched sound you'll get. It may also be indicative of a potential gear failure (after all our increasing noise, the bevel gear broke and the mixer 'froze'). If your mixer is under warranty, contact Kitchenaid. If it's out of warranty, then take it apart and do a diagnostic exam of the gearing. Whatever you find you should be able to fix yourself. Be sure to have the Kitchenaid Part Manual (Part No. 8212278 Rev D) on hand if you attempt to disassemble yourself. It also lists all the parts so that you can determine, which parts, if any have failed. You'd think that the Kitchenaid name would warranty their mixers for a lifetime... So much for quality in America today!
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