-Would there be any advantage to having more than one 'internal' network card? (in responsiveness of web)
No. One is more than enough unless you have a monstrous pipe to the 'net.
-Would dual (Xeon) processors give an advantage over a (faster) single AMD/P4 processor in responding to either web or file requests?
Yes, but whether you could discern it at the workstation is another matter. Dual processors always help in a multi user, multi request environment.
-also considering splitting the load between two servers, one servergateway, one fileserver, with half the lab & half the 'other' users on each...
The load's nowhere near high enough to warrant this.
Do you think 512MB ram sufficient?
No. v6.x SME chews more RAM than the previous versions. Besides, the more RAM you throw at it the more it will cache and the better the performance in a multi user, multi request environment. RAM is cheap. Put at least 1GB in it. I have 1.25GB in mine and it has really helped.
...do you think SATA will be noticeably better performing than ultra ATA?
No. Besides, increase your RAM and the performance of the drives becomes a moot point 90% of the time. If you're really concerned about disk performance then nothing beats SCSI in a server.
You don't mention AMD processor; I've had no problems using one in my home smeserver, do you have a take on AMD vs P4 for this usage?
At the same price point, buy whichever has a larger cache. Otherwise, raw GHz.
Lastly, you mention caching proxy service, is this 'automatic' or an add-on rpm?
SME's web proxy is automatic and transparent. You can turn it off, but there's no benefit to this.
...how to determine and configure best cache size?
Not my forte, but for 30-60 people I doubt you will need to touch it. See here:
http://forums.contribs.org/index.php?topic=14625.msg55908#msg55908