As far a noise goes, it is all about RPM. The faster the fan spins, the louder it will be. Larger fans are not quieter per se. The reason they seem quieter is because you can run them at a lower speed and still get decent airflow. I image the larger blades probably give you a lower frequency noise, but regardless, unless you plan to have a BUNCH of 40mms and run them at half speed, you are better off going with a larger fan. Do check the RPMs of the fans. The lower the RPM, the quieter, but at the expense of airflow. If your supply voltage is 15V, try getting two full speed fans and run them in series, that will lower their speed and each fan will only be running at 7.5V.
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