The Makerbot folks recommend that the extrusion width be atleast 1.5 times the layer thickness. Following that guideline, the Ultimaker 0.4mm nozzle should only do a 0.26ish mm layer. In practice, I have found this to be a good guideline.
layer height affects layer adhesion. for PLA and ABS you need to sqwish the layer into the previous layer to get adhesion which limits your max layer height.
if the nozzle is 0.4mm, you might get away with 70% of that as max layer height (0.28mm)
that's not far off the numbers tinsoldier and you yourself have already found.
personally I use 0.24, 0.16 and 0.08 depending on the quality i'm after.
i've run prints at 0.05 but it takes forever..
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Daid 306
Also depends a bit on how width you make your lines, 0.4 lines at 0.3 layers caused problems for me, but I think you could push out 0.6mm lines with 0.4mm layers just fine.
But you'll get limited by the maximum amount of volume of plastic you can heat and push out quite fast then.
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