While I'm not sure about Chaos, I can tell what sizes I used to magnetize my Grey Knights if that helps.
2 mm: Used to magnetize arms<->hands link and to magnetize searchlights and HK missiles on Razors/Rhinos. Tip: You don't need to drill hole through the hull of the rhino. Just make small, 0.5mm intendation on the underside of the hull and glue the magnet there.
3 mm: Used to magnetize backpack<->body and body<->arms links. Also used for some of the terminator arm<->hand links when terminator was holding something heavy, like Brotherhood banner.
4 mm: used to magnetize dreadnought arms to body.
Few notes: Use 3 mm magnets in all parts that you could consider lifting the figure from, 2mm will separate too easily in cases where it needs to hold the whole weight of the figure.
1 mm magnets are very much situational. They have very little strength, but you can use them for hatches etc (though you will need at least 2 pairs per hatch). They probably aren't strong enough to hold Predator sponsons, so I wouldn't buy them if I were you.
Also, most magnet sets sold by hobby stores are very costly compared to places that sell just magnets. Google for them or use ebay.
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