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The Emperor's Children on a tear, out for slaves to...well you know the rest.

The Death Korps to an extend, sur its not as bas as most armies mentionned here, however, think about it, what you are fighting is obviously human, but their soldiers are acting in almost inhuman ways at time, think about how they disregard their own troops and now consider that you are their enemy and finally, I don't picture the DKoK men to shout like SM or some IG regiments and their voices would be muffled by their masks either way, which brings the real last point, they are faceless, some of them look like armored skeletons, yeah there's scarier, but its still pretty unnevering.

I didn't read all five pages, so someone may have beat me to it.

I think death by Sisters of Battle Procreation Squads would be pretty scary. They're demanding!

My scariest opponent would have to be chaos.
Orks are scary but Khorne berserkers have them beat on insane bloodshed and violence.
Nids are scary but Nurgle demons have them beat just by how they devour with diseases.
Dark Eldar are scary but Slanesh demons will rape you and torture you with things you didn't even know existed in holes you didn't know you had.
Tzeentch and his magic would just be terrifying too because you really wouldn't have any idea what was going on there.
All in all most of the armies are scary but they mostly need to comply with the sideways physics of 40k, chaos doesn's even need to do that.... and i really dont like the idea of being raped by something that even has control of whether I die or not.