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Federer, the world number one, admitted that he let go for a moment against his 32nd-ranked opponent, allowing Almagro momentarily through a crack in the door.

 "I actually think I played better today than I did yesterday," said Federer, the 2005 champion, now 43-6 on the season with five titles.

 "The only problem was I had one really bad game, which then cost me the (second) set. It was a pity I couldn't create myself more chances in the second set."

   The Swiss player will run into the unseeded Hewitt for the second consecutive week after beating the Australian in the Montreal quarter-finals.

 The Aussie, coached by Federer's former mentor Tony Roche, rewrote his own recent history, defeating Spain's Carlos Moya 6-4, 6-2.

 That result gained revenge for a loss in the final five years ago at Cincinnati.

 It was all over in 77 minutes with Hewitt looking to become a serious threat for the US Open starting a week from Monday.

 James Blake will play a semi-final after defeating Sam Querrey 5-7, 6-4, 6-4. The ninth seed will take on Russian number five Nikolay Davydenko, who beat Spain's David Ferrer 6-2, 6-4. 

   Federer has his last 10 matches and stands 12-7 overall against Hewitt. But even that record is no cause for confidence.

 "I may have won them, but until last week we hadn't played for two years. There are plenty of guys who can make it hard for me to win here - and they start with Hewitt.

 "For me, it's 1-0, since we hadn't played since 2005," he said. "It was good to win last week and get an idea of how he plays."

   Hewitt knows what he's facing in his attempt to reach his first final since winning Las Vegas in early March.

 "Federer's the best player going around at the moment, and he's had the wood on me last nine, 10 times that we've played," said Hewitt, who is 29-12 this season.

 "That's the benchmark, though. That's what you're competing against and trying to put your best foot forward and give yourself a chance to play against the best guys such as Rog late in the tournament."

   Hewitt has been on a mission since hooking up with Roche earlier this summer and taking coaching via telephone as Roche waits in Sydney for the birth of a grandchild.

 Hewitt will be playing in his fourth semi-final this season.

 "I felt great physically, I really took it to him," said Hewitt. "I'm happy with how I'm hitting the ball."

   Federer, who was beaten in a second-round upset at the event last year by Andy Murray, is determined to take away the trophy before heading to New York for the last major of the season.

 "I'm not here to pick up matches, I'm here trying to win this tournament," he said. "This is a big one, I've had some struggles in the past here but I've won it before.

 "It's also the ultimate test because you've got the chance to play against the best in the world."

DPA