1. is it possible to take delivery in osaka and return in narita.Yes, some companies have kiosks at both airports, or allow returns through the mail.
renting at the airport you may get a cheaper daily rate, but the call charges will be very very high, e.g. 300 yen per min to the US with Softbank Global Rental.
Overall it will be cheaper to order from somewhere like Rentafone Japan before you go.
Softbank is a bad example as they have one of the highest international calling rates of all the services offered at Narita. Other companies, such as G-call have a significantly more reasonable 70 yen/min to the US.
Your best bet is to figure out your intended usage and then choose a service that fulfills your needs. If you only want the phone for emergencies or will primarily be receiving calls, then go with something with a low daily rate. If you are a heavy user than plans with higher daily rates typically have lower calling costs (Rentafone Japan included).
Actually Rentafone Japan may fit the OP's needs as they have a very reasonable overseas delivery charge (1000 yen) and have very competitive calling rates. Let us know what you choose and what you think of the service after you've tried it.