The World number one beat Croatian Donna Vekic 6-3 4-6 7-6 (7-4) at the Porsche Tennis Grand Prix.
Osaka will now face Anett Kontaveit, who was able to progress after Victoria Azarenka retired.
Petra Kvitova will face Kiki Bertens in the other semi-final.

Benzema moves to Al-Hilal following Al-Ittihad departure
Pakistan to boycott T20 World Cup group match against India
Dubai Basketball rounds off Family Day with another ABA League win
Man City and Villa slip up in title race, Man Utd win again
Justin Rose sails to wire-to-wire Farmers victory
