I've done some experimenting with this, and think I've made some progress.
First, there's the skinny from the guru web-sites. For effective air-cooling, you can get high-power fans (like the Vantec Tornado), and therefore use fewer fans. But that also means higher decibel levels (fan-noise).
If you increase the number of fans in strategically chosen parts of the computer case, you can decrease the average rpm's for all fans, maintain the same air-flow, and decrease the noise.
If you use larger fans, they move more air at significantly lower rpm's, reducing noise further.
The heat-capacity and heat-absorbing potential of air increases with greater pressure, and deteriorates in a vacuum. Therefore, it is possible to create a slightly pressurized case with larger intake fans moving more air CFM's or cubic feet per minute into the case, and smaller fans exhausting slightly less CFMs.
Putting a blow-hole directly over the CPU heatsink-fan (preferably with a screen-filter) will suck more air into the case (assuming that the CPU fan blows air onto the heat-sink rather than sucking it off (the heatsink).
I like the ThermalTake "Smart" fans, because they can be run independently with thermal sensors, or from a front-panel rheostat knob. You can get them in 80mm, 92mm, and 120mm sizes. I used to be prejudiced against "LED" fans -- and TT now makes a lot of them -- but what the heck -- you won't trip over your computer in the dark, and the fan quality is very high.
I have an old Gateway 2000 solid-steel full-tower case (vintage 1995) that I modded into an ATX P-4. It is so big that I was able to fit two 120mm aluminum "Heatsink" fans on the lower case-front, between the metal case frame and the plastic facie -- with screen filters between the fans and the facie. Then I fitted two 92mm fans under the power supply side-by-side for exhaust, cut a blow-hole in the side right over the CPU fan, and fitted a duct to the case-frame between the blow hole and the HSF -- so that the (old-style U-shaped) case shroud comes off for maintenance unobstructed by having a duct riveted to it.
I've never before had a case and fan setup that keeps things so cool, and because twin fans share the load, the entire rig is whisper-quiet. The CPU fan is a 92mm "UFO" model that has max-rpm's of 3,600, and it is attached to a TT PIPE101 heatsink-with-heatpipes assembly. Much better than a 70mm fan spinning at 6,500 rpm.