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I'll give it a shot. In rural communities both in Europe and the US 200 years ago, schooling was rare and many people were illiterate. Often the only times their names were put into writing were at births, deaths, and marriages (this was before written censuses or tax forms).

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This recording was often done by local officials or parish clerks who didn't see the names in writing often either. The spellings they put down were often their own interpretations of the spoken names and could vary in spelling.

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When these same name bearers emigrated to the US, they took these "wrong" spellings with them. Of course, not being able to read, they didn't know they were "wrong". Once in rural US communities, the same conditions may have prevailed for a long time, and it's not uncommon in genealogical research to see a rural US surname change in spelling over 2 or 3 successive generations.

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Another situation happened with non-English surnames. Upon people's arrivals in the US, the immigrations officials often didn't have the knowledge or patience to puzzle out correct spellings from people who may not have known them themselves. Or the name bearers may have initiated the changes, thinking a slight change in spelling might make their surname seem less "foreign".

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That's only a piece of it, but hope it helps.