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.

Mexico bounce Czechs out of World Cup with win
South Africa beat South Korea to reach World Cup knockout stage for first time
Qatar’s Assim Madibo gets 5-game ban for injuring Canada's Ismael Kone
Morocco earn comeback win over Haiti to reach last 32 as group runners-up
Vinicius fires Brazil into World Cup knockouts with win over Scotland
