it depends on the controler some are a recyling timer others are a spring dial. in the case of the spring dial lowering the fan below 60% can shorten the life of the fan and create the buzzing you are speaking off and are to be avoided if you want to lower the fan below 50%( i use one but i think its killing my fan and i have it set at 80% roughly)
a recycling timer just turns the power on and off quickly with preset time intervals and are very safe for fans usually cost about 20$ at the hydro store. although i am unsure whether they put off a buzzing or not.
What you really want is a Variac... Google it... I posted a thread here a while back when first learning about fans and what-not... The key is this... the cheap ones in the hydro-store are one approach which results in a stuttering stop/start at very small intervals... that's the simplest way I can explain it... And I think it also generates heat as a by-product... not sure on that part...
A variac on the other hand... actually transforms the voltage... so it's actually delivery less juice... but at a constanst/steady voltage.... no stuttering.... which is what kills your fans from what I hear.
One of the hydro catalogs I picked up has the true Variac from CanFan I believe... they want $299 for it... But search Ebay and the Net and they can be had for about $50 actually... So a FAR better solution from what I can tell.. for just a little more money in the big picture...
If I'm off my rocker and you have info to back it up.... please share.... but I gathered this info from a lot of researching... but I'm no electical engineer...